01 / Customer experience
A better arrival
A package that fits the order needs less void fill and creates a better unboxing experience. Protection stays part of the brief, especially for jars and products that need a rigid box.
Packaging & parcel economics
Stop paying to ship air.
How we helped Equip Foods right-size and source packaging to lower costs and improve the customer experience.
Equip Foods
$334KProjected annual savings
2027
2027
$1.22MTotal projected savings
2027–2029
2027–2029
Benefits
Right-sizing and better sourcing pay off beyond packaging costs.
A better packaging plan can improve the customer experience and reduce costs across packaging, parcel shipping and fulfillment. The Equip case study below shows the projected packaging and shipping savings.
02 / Packaging cost
Better fit, better sourcing
Choose package sizes that fit your most common order combinations. Through our network, we find the right manufacturers near your warehouses for competitive pricing and lower transportation costs.
03 / Shipping cost
Less weight and empty space
Oversized boxes can increase dimensional weight. Larger boxes and extra void fill also add actual weight. Right-sized boxes and mailers can lower your shipping costs.
04 / Fulfillment cost
Fewer packing steps
Removing unnecessary void fill reduces material use and packing time. A simpler pack-out can lower pick-and-pack fees when the 3PL’s pricing reflects the work required.
Equip Case Study
A fast-growing protein brand.A better way to ship.
Equip Foods is a protein powder and bar brand with mid-eight-figure annual revenues and rapid growth. The brand ships 50,000 orders per month. We introduced Equip to a 3PL, then worked with the team on packaging optimization after they launched.
73%of orders could use mailers
The biggest win was using the right packaging type.
We reviewed Equip’s most common order combinations and found that products without a need for rigid protection could move from boxes to mailers.
Equip had been using unbranded boxes supplied by the 3PL. This was also an opportunity to introduce branded boxes and mailers that fit the orders and create a better customer experience.
Before / Box
Extra space. Extra packing material.
A protein powder pouch shipped in an oversized box with paper void fill.
After / Mailer
A closer fit for the order.
A branded mailer carries eligible powder orders with less packaging and fewer packing steps.
One brand / The right package
Branded mailers and boxes.
Mailers for orders that suit them. Boxes for bars, jars and other orders that need more protection. Equip’s red branding carries across both.
The 2027 savings model
Where the $334K comes from
These projections cover packaging and parcel shipping. Fulfillment savings are not included.
| Cost component | Savings per order | Projected annual savings |
|---|---|---|
| Packaging | About $0.35 less per shipment on average | $247K |
| Shipping | About $0.17 less per mailer order | $87K |
| Combined projected annual savings | Across the recommended package mix | $334K |
Our process
Build the package plan around the order.
We model the fit, test real pack-outs and calculate delivery costs. Then we manage production, warehouse setup and replenishment.
01 / Measure and model
Model the best fit across the order mix.
We measure products as they are actually packed, including how pouches fold and how items fit together. Our proprietary fit model evaluates order combinations and packing configurations to find a practical set of box and mailer sizes. Product dimensions from an online catalog alone cannot capture that fit.
02 / Test the fit
Make sure the modeled fit works in practice.
We pack real products into the proposed boxes and mailers, covering common orders and combinations that are harder to fit. We check how easily each package closes, whether the products stay protected and whether warehouse staff can repeat the pack-out. Those trials refine the model before production.
03 / Model the full cost
Calculate the savings across delivery costs.
We model how smaller dimensions and lighter packaging change shipping charges, including moves into lower weight tiers. We also assess faster pack-outs and source packaging near the warehouses to reduce inbound transportation costs.
- Packaging prices and inbound transportation
- Dimensional weight and carrier weight tiers
- Void fill, packing time and pick-and-pack fees
$247K packaging + $87K shipping = $334K in projected annual savings for 2027.
04 / Execute and replenish
Keep the right packaging ready to use.
We forecast demand with the brand, accounting for seasonality and growth. We coordinate blanket purchase orders and production runs with manufacturers, then plan deliveries and safety stock across warehouse locations.
- Lock in production capacity and replenishment schedules
- Maintain safety stock across warehouse locations
- Set 3PL system rules that assign packaging by order mix
From strategy to execution
We put the packaging plan to work.
We carry the work through from fit modeling and sourcing to manufacturing, delivery and warehouse setup. Your team gets packaging ready to use, with replenishment plans and system rules that tell the 3PL which package each order needs.
Curious about your own shipping setup?
Start by sharing your historical orders, current packaging invoices and shipping rate card or charges.
Even if your packaging already fits well, we often find savings through our manufacturer network and opportunities to improve the customer experience.
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