Optimizing the Box: New Software Aims to Tackle E-commerce Packaging Waste
The relentless growth of e-commerce has brought with it a surge in packaging waste, prompting both environmental concerns and increasing regulatory scrutiny. Now, a new software solution developed by the Fraunhofer Institute for Material Flow and Logistics IML aims to address this challenge by optimizing the utilization of shipping cartons. Dubbed CASTN (Carton Set Optimization), the software is designed to accurately measure the volume utilization of shipping boxes, a critical factor as European regulations, like the upcoming Packaging and Packaging Waste Regulation (PPWR), begin to mandate a minimum volume utilization of 50 percent.
According to researchers at Fraunhofer IML, many companies currently fall significantly short of achieving optimal volume utilization, representing both an economic and regulatory risk. The software tackles this issue by providing a data-driven approach to packaging selection and configuration.
Analyzing and Optimizing Packaging Sets
CASTN begins by analyzing a company’s current volume utilization rates. It then assists in creating an optimized standard carton set tailored to the specific characteristics of their products and order structures. A key component of this process is a built-in data check, designed to ensure the quality and accuracy of the article, order and carton data used in the calculations.
The optimization is only as good as the data it is based on,explains Lukas Lehmann, project leader at Fraunhofer IML.CASTN therefore also supports companies in evaluating their own data basis and identifying weaknesses – a benefit that is often underestimated in practice.
The software aims to provide transparency and identify concrete optimization opportunities, particularly for companies struggling to meet the 50 percent volume utilization target. This is achieved through a detailed analysis of how products fit within different carton sizes, considering factors beyond simple dimensions.
Beyond Dimensions: A Holistic Approach to Cartonization
While the core function of CASTN is optimizing carton size, the broader field of “cartonization” – as highlighted by recent industry analysis – encompasses a more comprehensive approach to packaging. Modern cartonization technologies, as noted by Cahoot.ai, incorporate 3D simulation and consider real-world factors like product orientation, stacking limitations, and the potential for damage during transit. This goes beyond simply finding the smallest box. it’s about finding the *right* box, packed in the *right* way.
Several companies are already offering solutions in this space. ShipWise Cartonization, for example, focuses on minimizing wasted space and reducing dimensional weight charges, while ShipHawk emphasizes reducing material costs and selecting the smallest box that meets carrier standards. Perseuss describes cartonization software as a tool to determine the best box size, weight distribution, and packing sequence for each order, cutting shipping costs and reducing waste.
The benefits of optimized cartonization extend beyond cost savings and regulatory compliance. As Deposco.com points out, it also enables more sustainable packaging options and can improve shipping efficiency, labor productivity, and customer experience.
Industry Collaboration and Availability
CASTN was developed in collaboration with industry partners, including Hellmann Worldwide Logistics and Nordwest Handel AG, ensuring the software addresses real-world needs and challenges. The software is now available as a market-ready solution. Companies can utilize CASTN through research and development projects with Fraunhofer IML, or deploy it independently.
CASTN can be integrated into the service portfolios of third-party providers. The IGEPA Group is slated to be the first company to offer CASTN as a service to its customers. The software will be showcased at the E-Commerce Berlin Expo on and , 2026, at a joint booth with IGEPA Packaging.
The emergence of CASTN and similar cartonization technologies signals a growing awareness of the need for smarter, more efficient packaging solutions in the e-commerce era. As regulations tighten and sustainability concerns mount, optimizing the box – and everything that goes inside it – will become increasingly critical for businesses looking to thrive in a competitive market.
