cartonization

Cartonization is the process of determining the most appropriate carton size and packing configuration for a set of items to be shipped. It aims to maximize space efficiency, minimize product movement, protect contents, and reduce total transportation costs, often through automated or semi-automated decision systems.

Typical inputs include item dimensions (length, width, height), weights, and fragility, as well as carton specifications (available sizes, internal dimensions, maximum weight). The output is a packing plan: the number and type of cartons, suggested orientations, and packing instructions for each carton.

Approaches combine 3D bin packing and packing heuristics with optimization techniques such as mixed-integer programming or constraint programming. Software may integrate with warehouse management systems and enterprise resource planning to automate carton selection during order consolidation, picking, and packing.

Cartonization is widely used in e-commerce, consumer electronics, apparel, and logistics providers. Benefits include lower dimensional weight charges, reduced packaging material and waste, higher fill rates, faster packing cycles, and improved shipping reliability. It also supports sustainability objectives by optimizing carton usage.

Limitations include the need for accurate item data, handling of irregularly shaped or bulky items, and variability in late-order changes. Computational complexity can increase with large orders, requiring practical heuristics or rules of thumb. Ongoing data governance is essential to maintain cartonization performance.