Packaging & Load Optimizer

What the optimizer models

• Up to six orthogonal unit orientations inside the carton, filtered by your rotation and this-side-up constraints
• A configurable packing tolerance (default 0.125 in) so mathematically exact fits are not treated as packable
• Length-aligned, rotated, and mixed-column pallet patterns with height and weight limits, including partial top layers when weight is the binding constraint
• Standard pallet footprints and container/trailer interior presets, all editable or replaceable with custom values
• Dimensional weight with a configurable divisor, and optional cost inputs for cost-per-unit estimates

What it does not model

• Irregular product shapes or non-rectangular cartons
• Arbitrary-angle 3D bin packing or interlocked brick patterns
• Carton crush strength and structural engineering
• Live carrier rates or freight-rate APIs
• Floor-loaded (non-palletized) container optimization

How does the optimizer pick the recommended configuration?

It generates many candidate cartons around feasible integer packing layouts, evaluates pallet patterns and container loading for each, and scores the complete chain — unit package, carton, pallet, and load — against the objective you select. The winner of a single stage is never assumed to be the best overall configuration.

Do I need cost data to use the tool?

No. Without cost inputs the optimizer ranks configurations on physical efficiency such as units per pallet and cube utilization. When you add packaging, handling, parcel, or freight costs, it also computes an estimated logistics cost per unit.

What packing patterns does the optimizer evaluate?

Version one evaluates orthogonal packing: up to six unit orientations inside the carton, and length-aligned, rotated, and mixed-column grid patterns on the pallet and container floor. Arbitrary-angle or interlocked brick patterns are not modeled.

Why was a denser carton rejected?

Every candidate is checked against your constraints — maximum carton dimensions, carton weight, unit counts, and void percentage, plus pallet height and weight limits. Rejected candidates are listed with the specific constraint they violated so you can see why a seemingly denser option was not chosen.

How is dimensional weight handled?

You choose the DIM divisor (139, 166, or a custom value) and the tool computes dimensional and billable weight for the unit package and each carton candidate. Divisors differ by carrier and contract, so nothing is hard-coded.

What is the packing tolerance?

A configurable clearance (default 0.125 in) reserved along each carton axis. It prevents mathematically exact fits that are not physically packable — three 8.000 in units are not assumed to fit a 24.000 in carton.