Build packaging systems,
not scattered calculations.

Build from carton to pallet with linked outputs, validation checks, optimization, and reports.

Start a system See how it works

Carton

Primary pack dimensions
and material.

Case

Carton count and layout.

Shipper

Master box cube, weight, and strength.

Pallet

Pattern, load height, and utilization.

Validate

Strength, stability, and test-plan checks.

Optimize

Compare scenarios before committing.

Report

Traceable export with linked assumptions.

Illustrative example

One product, every step connected.

Follow an authored packaging example: 4 product units per carton, 24 cartons per shipping case, and 32 cases per pallet. These are illustrative assumptions, not a saved customer result.

Carton
Case Recipe
Shipping Case
Pallet Load
Validation

Carton → Case Recipe → Shipping Case → Pallet Load → Validation

Each step shows what it produces first. The "Send to..." line shows exactly what data carries forward to the next tool.

Actions

Download a report, save to a project, or send to another tool.

The strip is shown open here as an illustration; on the actual tool page it behaves like the live result action menu.

Illustrative basis: 24 cartons per full case, 0.60 lb per loaded carton, 1.60 lb case tare, and a 45 lb pallet. Case inside dimensions match the packed envelope; nominal outside dimensions use FEFCO 0203 allowances with 4.0 mm board. The selected eight-case layer is an example, not an optimized result.

01 Carton Builder

Carton

Primary pack structure, material, and dimensions.

Start with the product and primary pack requirements. feeds the case pattern

Send to Case Builder carries case-fit outside dimensions, loaded carton weight, units/carton

Case Builder receives the carton as a physical item: case-fit OD, loaded weight, and units per carton.

Open Carton Builder

Carton Builder **OUTPUT**
6.00 × 5.00 × 3.00 in
*0.60 lb loaded · carrier board*
OUT **case-fit OD + loaded carton weight + units/carton**

Internal

5.90 × 4.90 × 2.90 in

Units / carton

4

Material

SUS/CUK carrier board

02 Case Builder

Case Recipe

An arrangement of cartons, ready for a physical shipping case.

IN case-fit OD + loaded carton weight + units/carton feeds the shipper spec

Send to Shipper Builder carries packed envelope, carton count, arrangement, contents weight, and total units

Shipper Builder adds a physical container around the Case Recipe and keeps the pack-count chain attached.

Open Case Builder

Case Builder **OUTPUT**
15.00 × 12.00 × 12.00 in packed envelope
*14.40 lb contents · 24 cartons*
OUT **packed envelope + carton count + arrangement + contents weight + total units**

Pattern

3 × 2 × 4 (rotated cartons)

Cartons packed

24

Total units

96 product units

03 Shipper Builder

Shipping Case

Physical shipping case dimensions, weight, cube, and board strength.

IN packed envelope + carton count + arrangement + contents weight + total units feeds validation and pallet planning

Send to Pallet Calculator carries outside dimensions, gross packed weight, case-pack totals, board grade and strength inputs
Send to Box Strength carries board grade, wall/flute, ECT, caliper, outside dimensions, gross weight

The same shipper spec can feed pallet layout and compression checks without retyping dimensions or board data.

Open Shipper Builder

Shipper Builder **OUTPUT**
15.31 × 12.31 × 12.63 in
*16.00 lb gross · 32 ECT assumed*
OUT **shipper OD + gross weight + case-pack totals + strength inputs**

Style

FEFCO 0203 FOL

Board

Single wall · C flute · 4.0 mm assumed

Tare assumption

1.60 lb

04 Pallet Calculator

Pallet Load

Pallet pattern, quantity planning, and load height.

IN shipper OD + gross weight + case-pack totals + strength inputs feeds stability checks

Send to Pallet Stability carries pallet/package dimensions and weights, layers/grid, unitization, per-box positions, board info

Validation receives the palletized load, not just a count: geometry, weights, arrangement positions, and securing assumptions.

Open Pallet Calculator

Pallet Calculator **OUTPUT**
8 cases/layer × 4 layers
*32 cases · 3,072 product units · 557 lb gross*
OUT **pallet/load geometry + unitization + per-box positions + board info**

Footprint

45.94 × 36.94 in

Load height

50.52 in (excluding pallet)

Layer pattern

8 cases in a 3 × 3 grid, one space empty

05 Validation Tools

Validation

Box strength, pallet stability, and distribution test context.

IN pallet/load geometry + unitization + per-box positions + board info captures the evidence

Captured in the system record Strength, stability, and distribution-test evidence roll up into the saved packaging system.

See Systems

Validation Tools **OUTPUT**
Strength and stability checks
*Not run for this illustrative example*
OUT **stability + compression + distribution-test evidence**

Tilt screen

Not run

Stack result

Not run

Evidence

Calculate before accepting the design

Packaging Systems

The workflow becomes a system record.

Save a chain for quantity planning, scenario comparison, validation evidence, and reports. The authored example below uses the same carton, case and pallet assumptions as the workflow above.

Illustrative system

4-Pack Retail Example SKU

Draft Partial Complete Validated

Carton · Primary 4 product units/carton 6.00 × 5.00 × 3.00 in
Case Recipe 24 cartons/case 96 product units/case
Shipping Case 96 product units/case 16.00 lb gross · 32 ECT assumed
Pallet Load 32 cases/pallet 3,072 product units · 557 lb gross

Set one order quantity and the system rolls it up across the saved chain: product units, cartons, shipping cases, full and partial pallets, weight, and cube.

Plan your quantities

Enter the total order quantity and see how it flows through your packaging system.

Total order quantity (product units)

One partially filled shipping case. 88 product units of spare case capacity

1,250 Cartons 4 product units / carton

53 Shipping cases 96 product units / case

2 Pallets (1 full + 1 partial) 32 cases / pallet

5,000 Product units planned Matches the order target

At a glance

Level	Minimum for order	Configuration	Planned	Variance
Carton (Primary)	1,250	4 product units / carton	1,250	No extra cartons
Shipping Case	53	24 cartons / case · 96 product units	53	88 product units of spare case capacity
Pallet (Tertiary)	2	32 cases / pallet	2	1 partial pallet: 21 cases

Authored illustration only. No customer record is shown or saved; actual quantity plans use the ratios in your system.

Start Anywhere

Use the tools standalone, or save the result into a system.

Many users arrive for one calculation. PackCalc lets that answer become the first reusable building block in a larger packaging workflow.

View all tools

Core packaging tools

Carton Builder Create primary pack specs with structure, material, and dimensions. Open tool Case Builder Pack cartons into cases and reuse the resulting layout downstream. Open tool Shipper Builder Specify the physical shipping case for strength and pallet planning. Open tool Pallet Calculator Generate pallet patterns, load height, utilization, and count. Open tool Box Strength Estimate box compression performance and stacking safety. Open tool Pallet Stability Screen tilt angle, g-equivalence, and load stability. Open tool

Supporting utilities

ASTM D4169 Test Planner Statistics Suite Converters Dew Point Absolute Humidity Accelerated Aging

Connected Workflow

Start your first packaging system.

See how one connected workflow carries packaging decisions from carton to pallet, with validation and reporting context attached.

Build your first system Explore standalone tools

Build packaging systems,
not scattered calculations.