Model what right-sizing could be worth on your line
A scenario tool, not a promise. It applies a stated reduction range to the spend you enter so you can sanity-check whether an assessment is worth your time. The assumptions are written out in full below.
Cost scenario model
Runs entirely in your browser - no data leaves this page.
Modelled annual reduction
A scenario, not a forecast or a quote. It applies the assumed reduction range below to the figures you enter. Your actual result depends on your product, lanes, volumes and current spec, and is only knowable after an assessment.
What this model assumes
A number is only useful if you can see how it was produced. Here is the whole calculation.
The calculation
Annual spend is your monthly units x 12 x your cost per unit. The model applies a reduction percentage to that figure - nothing more sophisticated is happening.
reduction = base rate + volume factor- Base rate is set by the material you select, on the reasoning that mixed plastic-and-foam packs have more redundancy to remove than an already-optimized corrugated-only pack.
- A small volume factor is added, because tooling and setup costs amortize over larger runs. It is capped.
- The total is capped at 30%. The model will not show you a number we would not attempt to defend.
What it deliberately ignores
Treat the output as an order-of-magnitude prompt for a conversation, not a business case. It has no knowledge of:
- Your product's fragility, stacking load or drop height - the constraints that decide whether right-sizing is possible at all.
- Freight and cube, which are often the larger prize and are not in this figure.
- Whether your current pack is already efficient. If it is, the honest answer is that there is little to recover - and we will tell you so.
- Damage cost. Over-reducing material to chase a number and then failing ISTA is a net loss, not a saving.
Four levers our AI pulls on every account
AI material right-sizing
Models find the lightest compliant board grade and box dimensions for each SKU, cutting fiber use without risking failures.
Waste & scrap reduction
Optimized dielines and on-demand box making reduce trim waste and eliminate over-boxing across the line.
Freight & cube efficiency
Better cube utilization means more product per truck and pallet - often the largest single line of savings.
Sustainability incentives
Lower material and freight footprints reduce carbon-linked costs and unlock recycled-content savings.