Shipper Builder
Browse FEFCO-style corrugated shipper structures, compare options, and generate a preliminary outer shipper spec.
Learn about this tool
Learn about Shipper Builder
7 sections including 6 FAQs
Learn about Shipper Builder
7 sections including 6 FAQs
Shipper Builder is a catalog-first workspace for outer corrugated shippers, master cases, parcel shippers, wrap shippers, and shipper-level secondary cases. Browse a curated FEFCO-style shipper catalog, compare use cases and watchouts, then configure inside or outside dimensions, payload weight, and corrugated board grade for a planning-ready shipper spec. Saved specs become shipper records that Packaging Systems can connect to carton, case, compression estimates, and pallet decisions later.
How it works
Catalog Selection
The tool starts with a curated corrugated shipper catalog instead of a generic box-spec form. Search by FEFCO code or use case, filter by shipper use, use case, heavy-duty capability, and parcel suitability, or open the guided drawer when you need help narrowing options. Style cards, detail dialogs, and the compare drawer show best-use notes, watchouts, material compatibility, complexity, and assembly notes before you commit to a structure.
Preliminary Shipper Spec Generation
After you choose a shipper structure, enter known inside or outside dimensions, payload weight, and a corrugated board grade. The spec workspace estimates inside dimensions, outside dimensions, board caliper used for ID/OD conversion, blank size, board area, shipper tare, gross packed weight, cube, and a reference BCT value when material data supports it. The output is a planning specification for supplier discussion, PDF export, project save, Box Strength and Pallet Fit handoffs, and Packaging Systems assembly.
Material and Strength Guidance
Board grades and compression values are treated as planning guidance, not final certification. The tool can carry board grade, ECT, caliper, outside dimensions, and gross packed weight into Box Strength for a focused compression and working-load estimate, but final board grade, Box Maker Certificate assumptions, flute direction, closure method, compression performance, carrier requirements, and palletization fit must be confirmed with the converter and physical testing where required.
Example: FEFCO 0201 Master Shipper for 10×8×6 in Cases
Case dimensions: 10" × 8" × 6" outside, packed six cases per shipper in a 2×3 single-layer arrangement with 0.25" clearance.
Use the catalog filters for master case and case-to-pallet flow, compare FEFCO 0201, 0203, and full-overlap options, then continue with FEFCO 0201 RSC if its closure, stacking, and fulfillment constraints fit the project.
The spec workspace produces inside and outside shipper dimensions, selected corrugated board grade, nominal caliper, blank size, board area, estimated shipper tare, gross packed weight, downstream handoff values, and converter validation notes for the PDF spec sheet.
When to use this tool
- Choosing a corrugated outer shipper or master case style after carton or case dimensions are known
- Comparing master case, parcel shipper, wrap shipper, telescope, and heavy-duty corrugated structures before supplier discussion
- Creating a preliminary shipper spec with inside dimensions, outside dimensions, board grade, tare, gross packed weight, blank size, and board area
- Saving a shipper item to a project for later Packaging Systems planning
- Passing outside dimensions, gross packed weight, and board-grade data into Pallet Fit and Box Strength
- Preparing supplier RFQ inputs with clear converter validation notes
Common mistakes to avoid
- Treating the generated shipper spec as a production dieline. Final CAD, tooling, score allowances, joint geometry, closure details, and print bleeds must come from the converter
- Confusing inside and outside dimensions. Inside dimensions control product or case fit, while outside dimensions control pallet fit, freight cube, and downstream handoffs
- Assuming the reference BCT estimate verifies stack performance. Use Box Strength for a focused estimate and physical BCT testing for final validation
- Selecting a board grade from ECT alone without confirming caliper, flute direction, Box Maker Certificate limits, closure method, and supplier construction
- Sizing a shipper without checking upstream case/carton fit and downstream pallet efficiency in the Packaging Systems chain
- Skipping downstream validation for parcel, LTL, ocean, humid, long-storage, high-stack, or compliance-critical use cases
Frequently asked questions
What changed in the redesigned Shipper Builder?
The main experience is now catalog-first. You can browse, search, filter, compare, and directly choose a FEFCO-style corrugated shipper structure before generating the spec. Guidance still appears in style notes, material compatibility, board-grade choices, and converter or testing watchouts, but the user chooses the structure.
Does the Shipper Builder create a production dieline?
No. The output is a preliminary planning specification. Estimated outside dimensions, blank size, board area, tare, gross packed weight, and compression values are useful for early planning, supplier discussion, Packaging Systems assembly, and downstream tool handoffs, but production dielines, tooling, score allowances, tolerances, print bleeds, compression certification, and manufacturability must be confirmed by your converter and test lab where required.
How does PackCalc use shipper dimensions downstream?
Generated shipper specs use outside dimensions and gross packed weight for downstream planning. The Send to menu passes those values into Pallet Fit, and passes board grade, ECT, caliper, dimensions, and gross weight into Box Strength. Saved shipper specs also give Packaging Systems the shipper-level record needed to connect carton, case, shipper, strength, and pallet decisions without retyping dimensions.
How should I use the BCT value shown here?
Treat it as a reference estimate for planning. Shipper Builder uses available board-grade data to estimate compression, but Box Strength provides the focused compression and working-load workflow with environmental and duration assumptions. Final BCT performance depends on the finished box, board recipe, flute direction, closure, humidity, pallet pattern, and handling, so production qualification needs converter data and physical testing where required.
What is the difference between Carton Builder, Case Builder, and Shipper Builder?
Carton Builder defines the primary carton or light carton-level structure. Case Builder determines how cartons fit into a case or designs a case for a target quantity. Shipper Builder defines the corrugated outer shipper or master shipping box that feeds compression estimates, pallet planning, and Packaging Systems.
What is the manufacturer joint?
The manufacturer joint is the glued, stitched, or taped flap that joins the two ends of a corrugated blank to form a tube. It affects blank layout, converting, closure strength, and finished dimensions. PackCalc includes planning allowances, but final joint size and construction must come from the converter.
Related
Guide
How Corrugated Board Works: Flutes, Liners, and Compression
Guide
FEFCO Box Style Codes Explained
Guide
Corrugated Board Grades
Guide
Sustainable Packaging in 2024
Tool
Box Strength Calculator
Estimate compression strength and working loads for a generated shipper spec
Tool
Carton Builder
Select a primary carton structure and generate a preliminary carton spec
Tool
Case Builder
Pack cartons into cases before defining outer shipper specs