Pallet & Master Case Optimization

Cost Optimization & Packaging Optimization

Client Needs

Optimize pallet efficiency, reduce the number of master cases, and reduce headspace across a number of retail SKUs; analyze current packaging and propose new packaging.

The Challenge

Incomplete current-product info (pallet diagrams, case weights); newly enforced max pallet-height rules required re-assessing all patterns; many variables (re-arranging retail units, re-sizing cases).

Our Approach

  • Obtained samples of all ~9 SKUs and case weights
  • Ran TOPS analysis on all current master cases
  • Evaluated cases to downsize/eliminate
  • Created a proposal with SKU optimization list plus case and pallet efficiencies

The Impact

  • Eliminated 4 of 9 cases;
  • Increased pallet efficiency on 5 SKUs by 17%-62%.
  • First full SKU re-assessment for a client that uses co-manufacturers with no full-time packaging engineer.

Let’s Talk Efficiency Gains

Want to reduce production costs, increase throughput, or optimize your packaging line? Let’s connect.

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