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Warehouse Shelves from Above

Perseuss Blog

Expert insights on AI cartonization, warehouse efficiency, and fulfillment cost reduction.

 

Cartonization Isn’t a Packing Problem. It’s a Margin Problem

  • tom01419
  • Jun 21
  • 2 min read

Most Teams Are Asking the Wrong Question

When people think about cartonization, the first thing that comes to mind is:

"How do we fit items into the smallest possible box?"

But that’s not the question that protects your bottom line.The real question is:

"How do we pack orders in a way that maximizes margins?"

At Perseuss, we’ve worked with hundreds of warehouses and 3PLs. The biggest issue we see is that packing decisions are focused only on space, not savings.The Hidden Cost of “Good Enough” Packing

Here’s what happens when cartonization is treated as just a packing step:

  • You use oversized boxes that trigger dimensional weight charges

  • You miss opportunities to use cheaper carrier zones

  • You spend more on filler material and labor time

  • You undercut margins on lower-velocity SKUs

All of this leads to a silent drain on profits. Every inefficient shipment adds up.


A worker utilizes Perseuss Cartonization in a warehouse, combining cartonization logic and put-to-light guided packing, streamlining the packing process with efficiency and technology.
A worker utilizes Perseuss Cartonization in a warehouse, combining cartonization logic and put-to-light guided packing, streamlining the packing process with efficiency and technology.

Why Cartonization Should Be a Profit Driver

Smart cartonization does more than just suggest a box size. It helps optimize fulfillment around cost and margin. Here's how:

  •  Syncs with your real-time carrier rate cards

  • Adjusts based on SKU margin and order composition

  • Applies business rules like cold-chain, hazmat, or FBA constraints

  •  Reduces manual box overrides at pack stations

  •  Prioritizes cost-effective decisions over space-only logic

This approach ensures that your packing strategy supports your financial goals

Real-World Results

One of our 3PL customers saw a 14 percent drop in parcel spend within 60 days.They didn’t change their warehouse layout. They didn’t change their packaging materials.They simply started cartonizing with margin in mind using Perseuss.

This isn’t just about saving space. It’s about creating operational leverage.

Connect Your Box Logic to Your Business Logic

Cartonization isn't a background task anymore. It's a key part of your cost structure.

And the good news?


You don’t need to overhaul your warehouse software. Perseuss plugs into your existing WMS or TMS using simple APIs and starts delivering value from day one.


Want to Learn More? Schedule a demo with our team


 
 
 

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