Carton Size Optimisation Calculator

Work out carton size optimisation instantly with clear inputs, formula shown and shareable results.

About Carton Size Optimisation Calculator

Carton size is driven by the arrangement of products inside it. Choosing a near-cubic arrangement minimises surface area for a given volume, which minimises board consumption and gives the best compression strength per unit of board. Clearances of a few millimetres per axis allow for tolerance and flap thickness.

Formulas

Carton dimensions

Internal L x W x H = (nx x product L + clearance) x (ny x product W + clearance) x (nz x product H + clearance)

Fill efficiency

Fill % = product volume x 100 / carton volume

Worked example

With the default values below, Carton Size Optimisation Calculator returns Carton Volume of 0.01323. Change any input above and every figure here is recalculated in your browser.

Inputs used

Product Lengthminimum 1 mm: 120 mm
Product Widthminimum 1 mm: 80 mm
Product Heightminimum 1 mm: 45 mm
Units Per Cartonminimum 1: 24

Results

Carton Volume: 0.01323
Internal Carton Dimensions: 368 x 248 x 145 mm
Fill Efficiency: 78.35%
Product Arrangement: 3 x 3 x 3

Step by step

1Values used
2Carton dimensions
3Fill efficiency
4Carton Volume= 0.01323
5Internal Carton Dimensions= 368 x 248 x 145 mm
6Fill Efficiency= 78.35
7Product Arrangement= 3 x 3 x 3

Assumptions and limits

The result is derived only from the 4 inputs listed above. Anything not among them is not part of the calculation.
In particular, this calculator does not take inflation, tax, fees or charges or compounding frequency into account.
Figures are rounded for display to 5 decimal places, so totals built from several rounded parts can differ slightly from the unrounded arithmetic.

How these calculators are built and tested is described on the Methodology page. If a figure looks wrong, please report it.

Frequently Asked Questions

Why aim for a cubic shape?

A cube has the smallest surface area for a given volume, so it uses least board. Long thin cartons use more board, cost more and are weaker in stacking.

Should the carton be sized to the product or to the pallet?

To both. A carton that fits the product perfectly but tiles badly on a pallet wastes far more in freight than it saves in board. Check the pallet pattern before fixing the case size.