KolliPack

Full Packaging Workflow

Full Packaging Module

Workflow shell using chained steps. Container and Bag behavior is preserved, and Palletization is now embedded using the same step-scoped approach.

Interactive article case
216 or 240 Cartons per Pallet?
A bounded 12-carton CapePack reference case with two shared KolliPack shipping-case geometries and a linked 48 × 40 in pallet calculation. Choose another Box Design Mode alternative to see the pallet and container results recalculate.
PDF Report · Plus
Packaging Flow Summary
Final capacity: 240 base products / pallet
Box
12 base products / box
20.32 × 18.32 × 8.64 in · 27 lb
Pallet
20 boxes / pallet
240 base products / pallet
48 × 40 × 48.7 in · 540 lb
Final capacity per pallet
240 base products / pallet
20 boxes
Packaging Flow Summary 240 base products
Box
12 base products / box
20.32 × 18.32 × 8.64 in · 27 lb
Pallet
20 boxes / pallet
240 base products / pallet
48 × 40 × 48.7 in · 540 lb
Final capacity per pallet
240 base products / pallet
20 boxes

Step 1

Container Selection Selected for next step
Selected for workflow
Designed Container — 20.32 × 18.32 × 8.64 in — 12 units per parent | 12 total base units | 27 lb gross
Inputs changed. The displayed result is stale until you run the tool again.
How to use this tool Modes, rotation restrictions, result interpretation, and good input practices.

What the tool does

The Container Selection Tool checks how many identical products fit inside a rectangular packaging item such as a box, crate, container, or trailer.

How to use the modes

Single mode tests one selected packaging item.

Optimal mode searches a packaging catalogue and ranks suitable options for the required quantity.

Single: Product + 1 packaging → result Optimal: Product + qty + catalogue → Top 5
  • Use Single mode when you already know which packaging to test.
  • Use Optimal mode when you want the tool to recommend candidates.
  • In Optimal mode, select a Top 5 candidate to generate the 3D view.

Rotation restrictions

Rotation permissions define which original product dimension may be placed vertically during packing. Disable a rotation if the product cannot safely be placed in that orientation.

R1
Length vertical R2
Width vertical R3
Height vertical

Interpreting results

The 3D image is a decision-support representation of the packing logic. Physical validation is still recommended for critical packaging decisions.

Max qty
Maximum units that fit Efficiency
Used product volume Total weight
Product load + packaging weight Payload usage
Product load vs. max payload Remaining capacity
Extra units that could fit
Use internal packaging dimensions for fit calculations. Dimensions are expected in millimetres and weights in grams. A high volumetric efficiency is useful, but the final choice may also depend on protection, handling, branding, transport, and quality requirements.
Product
Manual dimensions with selectable units, or product catalogue selection.
Design calculates internal dimensions; Single and Optimal evaluate existing containers.
Product shape affects the 3D visualization only. Packing calculations use the entered rectangular bounding dimensions.
Base product unit
Restriction means which original product dimension may be placed vertically.
Additional parameters
Optional product dimensional allowance.
Container
Manual size with selectable units, or catalogue selection from BOX, CRATE, CONTAINER, or TRAILER types.
Packaging weight and max payload are optional. They are used only for the weight and payload report.

3D rendering is generated only after selecting one Top 5 candidate.

Used only to calculate the carton's external dimensions. A selected board supplies a reference caliper; manual input overrides it. Blank uses the 4 mm default assumption.
Used for the estimated empty RSC carton tare; a resolved caliper may prefill Box thickness, and the final thickness controls external dimensions.
Internal length, width, and height are calculated outputs in Design Mode.
Designed container
Calculated internal bounding box shown as a Regular Slotted Container.
20 × 18 × 8 in
4 × 3 × 1 · W × L × H · Cubicity 0.40
Interactive 3D result
Detailed analysis internal and external carton dimensions
Internal dimensions20 × 18 × 8 in
External dimensions20.32 × 18.32 × 8.64 in
Box thickness0.16 in
Net contents27 lb
Empty carton tareNot included
Gross carton weightNot available
Carton tare sourceNot included
Container design alternatives
Ranked by cubicity, then additional capacity, volume, and a stable key. Values closer to 100% are more balanced.
RankArrangementOrientationDesiredDesignExtraInternal L × W × HCubicityEfficiencyNet content weightEmpty carton tareGross carton weightMax base units / pallet
13 × 2 × 2W × L × H1212015 × 12 × 16 in0.751.0027 lb———
23 × 2 × 2L × W × H1212018 × 10 × 16 in0.561.0027 lb———
32 × 2 × 3L × W × H1212012 × 10 × 24 in0.421.0027 lb———
44 × 3 × 1W × L × H1212020 × 18 × 8 in0.401.0027 lb———
54 × 3 × 1L × W × H1212024 × 15 × 8 in0.331.0027 lb———
66 × 2 × 1W × L × H1212030 × 12 × 8 in0.271.0027 lb———
74 × 1 × 3W × L × H1212020 × 6 × 24 in0.251.0027 lb———
86 × 2 × 1L × W × H1212036 × 10 × 8 in0.221.0027 lb———
94 × 1 × 3L × W × H1212024 × 5 × 24 in0.211.0027 lb———
106 × 1 × 2W × L × H1212030 × 6 × 16 in0.201.0027 lb———
113 × 1 × 4W × L × H1212015 × 6 × 32 in0.191.0027 lb———
123 × 1 × 4L × W × H1212018 × 5 × 32 in0.161.0027 lb———
136 × 1 × 2L × W × H1212036 × 5 × 16 in0.141.0027 lb———
142 × 1 × 6W × L × H1212010 × 6 × 48 in0.131.0027 lb———
152 × 1 × 6L × W × H1212012 × 5 × 48 in0.101.0027 lb———
1612 × 1 × 1W × L × H1212060 × 6 × 8 in0.101.0027 lb———
1712 × 1 × 1L × W × H1212072 × 5 × 8 in0.071.0027 lb———
181 × 1 × 12L × W × H121206 × 5 × 96 in0.051.0027 lb———

Step 2

Palletization Selected for next step
Selected for workflow
Manual Pallet | Block / column — 48 × 40 × 48.7 in — 20 units per parent | 240 total base units | 540 lb gross
How to use this tool Inputs, stacking limits, result interpretation, and practical palletization checks.

What the tool does

The Palletization Tool estimates how many identical cartons fit on a pallet footprint and how many layers can be stacked within the allowed height.

Required inputs

  • Carton length, width, and height in mm.
  • Pallet length, width, and height in mm.
  • Max stack height in mm: the finished palletized-load height, including the pallet.
  • Optional carton weight and max bottom-carton load in g.

How to read the result

Total cartons Cartons/layer Layers Pallet floor usage Stack volume usage

The first option is the best ranked result. You can click another result row to redraw a different pallet pattern.

Good engineering practice

  • Use external carton dimensions when checking pallet capacity.
  • Include pallet overhang only when it is explicitly allowed by handling and transport rules.
  • Validate load stability, wrapping, fork handling, and customer-specific restrictions before release.
The 3D view is a clean engineering estimate. Final pallet approval should still consider real carton strength, center of gravity, transport vibration, and warehouse handling.
Carton / Box
Use manual carton dimensions in the selected unit, or select a canonical catalogue BOX/CRATE.
Advanced carton parameters
Optional weight and compression settings for bottom-carton load checks.
Show / hide
Optional. Used for the bottom-carton load check.
Optional. Leave empty when no compression limit is known.
Pallet
Use manual pallet dimensions or select a PALLET from the packaging catalogue. Dimensions are in mm.
Default: 150 mm
Optional carton load only; excludes the empty pallet.
Advanced parameters
Optional pallet overhang settings.
Result
Recommended pallet layout with practical capacity, height, and load indicators.
Palletization result
Cartons per pallet
20 pcs
Layers
5
Cartons/layer
4
Stack height
48.7 in
Actual pallet load
540 lb
Maximum pallet load
2000 lb
Load utilization
27.0%
Limiting constraint
Geometry
Interactive 3D result
Detailed analysis recommended layout, utilization and load check
Recommended palletization
Pallet floor usage: 77.55% | Stack volume usage: 75.29% | Alternate layer possible: No | Bottom load check: Not checked | Pallet load utilization: 27.0%
Cartons per pallet 20 pcs
Actual pallet load 540 lb
Maximum pallet load 2000 lb
Load utilization 27.0%
Limiting constraint Geometry
Main layer cartons 4 pcs
Alternate layer cartons 4 pcs
Total palletized-load height 48.7 in
Carton arrangement height 43.2 in
Pallet floor usage 77.55%
Stack volume usage 75.29%
Bottom-carton load check Not checked
Max bottom-carton load Not available
Bottom-carton load limit Not provided
Validate final stability, wrapping, handling, and customer-specific transport restrictions before release.
Palletization Results
Click a row to redraw another pallet layout. Repeated visible renderings are collapsed into one option.
Option Main layer Alternate layer Layers Cartons per pallet Alternate layer possible Floor usage Volume usage Load check Max bottom load Actual pallet load Maximum pallet load Load utilization Limiting constraint
Option 1 4 4 5 20 No 77.55% 75.29% Not checked — 540 lb 2000 lb 27.0% Geometry
Option 2 4 4 5 20 Yes 77.55% 75.29% Not checked — 540 lb 2000 lb 27.0% Geometry
Option 3 4 4 5 20 Yes 77.55% 75.29% Not checked — 540 lb 2000 lb 27.0% Geometry