Cartonization is the process of determining the ideal packing configuration and packaging size for the unique combination of items in each order. <\/p>\n<\/div>\n\n\n\n
Cartonization is a key capability in modern warehouse management systems<\/a> (WMS), as it: <\/p>\n\n\n\n Cartonization plays a vital role in the overall ecommerce logistics workflow, enabling a more efficient packing process. <\/p>\n\n\n\n It involves measuring the dimensions of every product that can be shipped out (including width, length, and height), and noting other characteristics that could impact the packing process, such as fragility<\/a>, shape, or material. Using this data, either through manual calculation or a software\u2019s algorithm, a business determined the optimal packaging type and size for each order\u2019s particular set of items. <\/p>\n\n\n\n In this way, cartonization helps brands avoid sending out items in needlessly-large boxes (which inflates shipping costs and leaves lots of empty space for the item to move around during transit) or unnecessarily small ones (which could break open during shipping and threaten the integrity of the items inside). <\/p>\n\n\n\n Cartonization software automates the packaging selection process with the help of an advanced algorithm that accounts for a few key variables to select the ideal packaging conditions. These variables include: <\/p>\n\n\n\n It then recommends the ideal packing configuration to make the most of available space and ensure items are transported safely. It also ensures cost-efficiency, as it helps reduce packaging waste and minimise additional courier fees. <\/p>\n\n\n\n Most cartonization software solutions include the following core functionalities to support packaging optimisation: <\/p>\n\n\n\n You can find basic cartonization tools that offer simple packing recommendations using fixed parameters. While this satisfies its purpose to some extent, it comes with limitations since it doesn\u2019t account for the complexities associated with mixed item shipments and custom packaging. This makes it suitable for businesses selling just a few types of products and often handle predictable or single-item shipments. <\/p>\n\n\n\n Meanwhile, advanced cartonization tools are capable of handling more complex packing requirements. They leverage AI to make real-time, data-driven packaging decisions to optimise packing efficiency and reduce the number of cartons needed. <\/p>\n\n\n\n As such, advanced cartonization tools can seamlessly handle custom packing requirements and assign multiple SKUs to a single box. They use historical data to create new configurations and constantly optimise your packaging recommendations. This makes them ideal for businesses dealing with a diverse product mix that\u2019s constantly evolving, and for smaller operations as well.<\/p>\n\n\n\n While it may seem easier or faster to pack products in any container you have on hand, cartonization is better for your brand in the long run. Here are just some of the benefits of cartonization for ecommerce businesses, and why you should take the time to invest in it. <\/p>\n\n\n\n Cartonization tools make optimised packaging suggestions to maximise space utilisation in packing, and help you save money in the process. They recommend the perfect box size for each item or order, so that there\u2019s minimal empty space inside each package. This allows you to minimise the use of oversized boxes and effectively reduce dimensional weight<\/a>. <\/p>\n\n\n\n Cartonization also ensures that you\u2019re fitting multiple items in the same box, so you\u2019re packing orders as tightly as possible and making use of all available space. As a result, you can cut down on packaging costs and avoid the added cost of a split shipment, since you\u2019re not using multiple boxes to ship out the same order. These are highly effective strategies to reduce shipping costs<\/a> without sacrificing fulfilment speed, which ultimately helps you boost profitability. <\/p>\n\n\n\n \u201cShipping can be complicated, but our Merchant Success Manager has always helped us find solutions. When we were experiencing issues with DIM weight doubling our shipping costs, I spoke with my Merchant Success Manager about it, he promised to find a solution \u2014 and he followed through! ShipBob took time to investigate the issue, and they helped us understand how to reduce DIM weight by reducing packaging weight and size.\u201d<\/em><\/p>\n\n\n\n John Greenhalgh, Co-Founder of A Year of Dates <\/p>\n<\/blockquote>\n<\/div><\/section>\n\n\n\n The ecommerce industry is one of the biggest consumers of plastic packaging, with forecasts suggesting that it will produce 4.5 billion pounds of plastic in 2025<\/a>. In addition to using eco-friendly packaging<\/a> materials, brands that leverage cartonization further reduce their environmental impact.<\/p>\n\n\n\n With cartonization algorithms recommending optimal packaging configurations, you can fit more orders into a single container, eliminating the need to use another box or polymailer just to ship out all the items in an order. This means you use up fewer materials, which reduces packaging waste and lowers your carbon emissions. <\/p>\n<\/div><\/section>\n\n\n\n With cartonization software automatically determining the ideal packaging configurations for your orders, it takes the guesswork out of the packing process. This means packers don\u2019t have to rely on tacit knowledge or trial-and-error to decide which items to pack with what, how many items should go in a certain box, which box and packaging materials to use for the order, and more. <\/p>\n\n\n\n This dramatically reduces the time taken to pack orders for shipping, which in turn improves warehouse efficiency<\/a>. Saving just a couple of minutes for each order could add up to significant time savings across your fulfilment process. <\/p>\n\n\n\n \u201cRegarding warehouse operations, ShipBob provides technology that empowers every warehouse worker. These workers not only receive information on which items to pick and which box to use, but they also have access to a visual aid though a GIF, guiding them on the optimal positioning of items within the box for maximum efficiency.\u201d <\/em><\/p>\n\n\n\n Ali Shahid, COO of Our Place <\/p>\n<\/blockquote>\n<\/div><\/section>\n\n\n\n With shipping couriers often charging for shipments based on dimensional weight, this can make shipping oversized<\/a>, bulky, or irregularly-shaped products particularly expensive. Cartonization tools can consider the unique shape and size of each product to determine the best way to pack it to reduce dimensional weight and save money. <\/p>\n<\/div><\/section>\n\n\n\n Throwing products in any size box or polymailer is the culprit behind many bad unboxing experiences<\/a>. If the box is too small, the contents could get crushed or break out of the package in transit; if the box is too large, the products could be jostled and broken during shipping. <\/p>\n\n\n\n Cartonization helps you strike the right balance with accurate packaging that prevents shipping damage<\/a> minus the excess packaging waste. It lets you offer consistent, secure, and branded packaging that ultimately boosts customer satisfaction. <\/p>\n\n\n\n PetLab Co.\u2019s<\/a> products, for example, came in metal tins and bottles, which were regularly getting dented during shipping. Once PetLab Co. partnered with ShipBob for fulfilment, they worked with the ShipBob team to determine that they needed sturdier boxes and that their box sizes needed to be optimised to reduce rattling in transit. <\/p>\n\n\n\n The team also started mapping out which order combinations would require geami paper or extra dunnage or both to provide additional cushion when shipping out orders. This streamlined the packing process and ensured that orders were safely delivered to their customers in their intended form. <\/p>\n<\/div><\/section>\n\n\n\n As a leading omnifufillment platform, ShipBob leverages advanced cartonization technology to optimise the packing process and minimise packing mistakes<\/a> for thousands of ecommerce brands. Here are just some of the ways that ShipBob helps brands save time, money, and effort in fulfilment and beyond. <\/p>\n\n\n\n ShipBob\u2019s WMS<\/a> features built-in algorithms to optimise the packing process. The data-driven packing workflow draws on your brand\u2019s specific inventory and order data to automatically choose the best packaging<\/a> for each order, recommending boxes based on size, material, and other factors. That way, your packing team can pack orders to make the most use of space, allowing you to reduce shipping costs. <\/p>\n\n\n\n You can easily determine which items should be packed together, which ones should be packed separately, which packing materials should be used, and more. This significantly speeds up your packing and fulfilment operations, all contributing to faster fulfilment. <\/p>\n\n\n\n \u201cOne of my favorite things about ShipBob is the visibility, one example of which is receiving a breakdown of how much it costs to fulfil each of our items. ShipBob uses a Cubiscan, so they have the correct measurements of each product. From there they say, \u201cBased on these dimensions, this specific product mix will be packed in this specific box size. Here is the rate.\u201d So, by that system, we know that one of our bottles is going to cost us let\u2019s say $4 to pick, pack, and ship.\u201d<\/em><\/p>\n\n\n\n Cesar Contreras, Head of Supply Chain of Wholesome Goods <\/p>\n<\/blockquote>\n\n\n\n ShipBob\u2019s customisation suite<\/a> provides you with endless options for optimising your packaging on top of cartonization. You can ship out orders in custom branded packaging<\/a> to maintain a consistent and premium look and feel for all your orders, and ShipBob\u2019s proprietary box algorithm will always use a triple Cubiscan process to recommend the ideal packaging option based on product dimensions, weights, and your chosen SKU-level packaging preferences. <\/p>\n\n\n\n You can also create ready-to-ship kits containing multiple SKUs to speed up the fulfilment process. You even have the option to add marketing inserts with special promotions or even include customised gift notes with every order. This allows you to create a truly personalised unboxing experience while still making use of our cartonization technology to streamline the process. <\/p>\n\n\n\n\n
Let\u2019s define cartonization in ecommerce logistics <\/h3>\n\n\n\n
![\"\"](\"https:\/\/www.shipbob.com\/au\/wp-content\/uploads\/sites\/33\/2025\/03\/Prymal-packing.jpeg?w=1280\")
<\/figure>\n\n\n\nHow cartonization software works (+ types) <\/h2>\n\n\n\n
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Key components of cartonization software <\/h3>\n\n\n\n
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Basic vs. advanced cartonization software <\/h3>\n\n\n\n
Benefits and applications of cartonization in ecommerce <\/h2>\n\n\n\n
Reduce shipping costs through optimised packaging <\/h2><\/div>
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Limit waste and environmental impact <\/h2><\/div>
Sharpen up warehouse efficiency <\/h2><\/div>
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Reduce dimensional weight charges <\/h2><\/div>
Improve your customer experience with accurate packaging <\/h2><\/div>
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<\/figure>\n\n\n\nHow ShipBob unlocks cartonization benefits for ecommerce brands <\/h2>\n\n\n\n
Advanced cartonization algorithms in ShipBob\u2019s WMS <\/h3>\n\n\n\n
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Custom packaging solutions for brand consistency <\/h3>\n\n\n\n
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<\/figure>\n<\/figure>\n\n\n\nInventory Placement Program for cost-effective shipping <\/h3>\n\n\n\n
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