A packaging redesign that paid for itself in one container

Cubic metres, not weight, price most consumer-goods ocean freight. Anything that improves cube utilisation drops straight into margin.

We remodelled the master carton against a 1200×1000 pallet footprint and found 11mm of dead width. Removing it took us from 8 to 10 cartons per layer.

Net effect over the season: one fewer 40ft container, about $3,100 in freight and roughly $900 in handling, against a $1,400 tooling change.