Carton optimization pilot program identifies critical space savings

Case Studies


A key client wanted OIA to improve its packaging quality while reducing space within its shipping containers. Initially, their containers utilized 43.8 M2 of space, with 468 total units per cubic meter. These metrics created unnecessary shipping costs, so OIA established a carton optimization pilot program to identify potential savings

Solution – Carton Optimization

OIA’s packaging team worked closely with Asian paper mills to create a more durable box with superior resistance to external forces. The new Opti-box featured stronger construction in the wall liner so that each carton utilized space more efficiently and didn’t break down during transit. This engineering solution resulted in a smaller carton with more products per box!

OIA can analyze a supply chain to identify immediate savings opportunities and take advantage of them within 2-3 months. Subsequent phases, such as redesigning a full carton suite, may take longer but will provide even greater, longer-lasting supply chain efficiencies.  Timelines for each optimization pilot program are truly dependent upon the customer.

Benefits of Carton Optimization

Carton optimization leads to better product containment, improved product densities per carton, and reduced transportation cost per product unit!

OIA has built out its apparel carton supply chain over time to keep box prices competitive, and network support for carton optimization remains robust. We’ve also invested in our sustainability capabilities, which include carbon reporting and advanced reporting for paper, fiber, and other key metrics.

Carton optimization saved 20,500 boxes and reduced each container’s used space from 43.8M² to 29.0M². This resulted in an improved cost per unit from origin to destination, with transportation savings per unit measuring $0.021.

Wasted space?

OIA will analyze your supply chain to identify unique savings opportunities.