Right-Sizing Your Boxes: Cut Void Fill, Pack Time, and Freight

• Void fill: paper, air pillows, or peanuts to fill the gap
• Labor: the seconds each packer spends filling the gap
• Freight: carriers bill parcel shipments on dimensional weight, the box’s length × width × height divided by a carrier divisor (commonly 139)

Dimensional weight example

Same product, six fewer billable pounds per package.

1. Rank SKUs by volume. Start with the 10 to 20 SKUs you ship most.
2. Measure each product. Length, width, and height, plus any inserts or packing lists.
3. Compare to the current box. Note the open space on each side.
4. Flag the gaps. Any SKU with more than 1/2 inch of open space on a side is a candidate.
5. Group similar sizes. Several SKUs often share one new box size. Fewer sizes means simpler inventory.
6. Quote and sample. Order samples of the new sizes and pack real product.
7. Measure the result. Re-time the pack, track void fill use, and compare freight bills for 30 days.

• Void fill saved per box × boxes per year
• Seconds saved per box × boxes per year ÷ 3,600 × hourly wage
• Billable pounds saved per box × your freight rate per pound × parcel boxes per year

Add the three. Report the total as a dollar figure your Plant Manager will recognize.

Want a right-sizing review? Send us your top 20 SKUs with product dimensions.

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