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Here are the four areas to check, and how to tell where your savings are hiding.","See where your packing process is costing you. We break down four areas shippers can improve, from SKU data to carrier terms, and how to find the savings.","6fdaa4cd-e50b-467c-af06-7ab551f7f67c",{"id":559,"alt":560,"name":13,"focus":13,"title":13,"source":13,"filename":541,"copyright":13,"fieldtype":561,"meta_data":562,"is_external_url":222},231397794064687,"Packing Control System Diagram","asset",{"alt":560,"size":563},"2744x1098","Why 2026 Is the Year Packing Gets Its Own Control System",{"type":440,"attrs":566,"content":567},{"backgroundColor":457},[568,578,588,596,611,642,656,677,686,721,729,738,746,763,771,823,831,840,859,878,887,895,957,966,974],{"type":443,"attrs":569,"content":570},{"textAlign":457},[571],{"text":572,"type":447,"marks":573},"Packing deserves its own dedicated system, a Packing Control System (PCS), the same way picking, transportation, and inventory already have theirs. Here's why.",[574],{"type":575,"attrs":576},"textStyle",{"color":577},"#000000",{"type":579,"attrs":580,"content":582},"heading",{"level":581,"textAlign":457},3,[583],{"text":584,"type":447,"marks":585},"Three Pressures, One Bottleneck",[586],{"type":575,"attrs":587},{"color":577},{"type":443,"attrs":589,"content":590},{"textAlign":457},[591],{"text":592,"type":447,"marks":593},"Three forces are converging on pack stations right now, and none of them are going away.",[594],{"type":575,"attrs":595},{"color":577},{"type":443,"attrs":597,"content":598},{"textAlign":457},[599,606],{"text":600,"type":447,"marks":601},"Carriers changed the rules, not just the rates.",[602,604],{"type":575,"attrs":603},{"color":577},{"type":605},"bold",{"text":607,"type":447,"marks":608}," Rounding used to work in a shipper's favor. Before August 2025, a 10.4-inch box rounded down and a 10.5-inch box rounded up. Today, a box at 10.1 inches rounds all the way up to 11, which can significantly increase your cost to ship that box. Once you add up cubic surcharges and fuel surcharges even shippers with the strongest of negotiated rates absorb new cost increases they can't negotiate their way out of.",[609],{"type":575,"attrs":610},{"color":577},{"type":443,"attrs":612,"content":613},{"textAlign":457},[614,620,625,637],{"text":615,"type":447,"marks":616},"Compliance is arriving on a deadline.",[617,619],{"type":575,"attrs":618},{"color":577},{"type":605},{"text":621,"type":447,"marks":622}," The EU's ",[623],{"type":575,"attrs":624},{"color":577},{"text":626,"type":447,"marks":627},"Packaging and Packaging Waste Regulation (PPWR)",[628,635],{"type":629,"attrs":630},"link",{"href":631,"uuid":632,"anchor":457,"custom":633,"target":634,"linktype":28},"/posts/how-to-achieve-ppwr-compliance-through-packaging-process-control","0ce3e790-ee42-40aa-bc7a-cb4e22790c9c",{},"_blank",{"type":575,"attrs":636},{"color":577},{"text":638,"type":447,"marks":639}," doesn't just target materials, it penalizes packages that aren't at least 50% full. At least a dozen U.S. states are drafting their own extended producer responsibility (EPR) laws modeled on it. Teams building new EU facilities are already designing around these regulations. U.S. operations should prepare to do the same, especially if they ship internationally.",[640],{"type":575,"attrs":641},{"color":577},{"type":443,"attrs":643,"content":644},{"textAlign":457},[645,651],{"text":646,"type":447,"marks":647},"Gen Z buys differently, and packaging is the tell.",[648,650],{"type":575,"attrs":649},{"color":577},{"type":605},{"text":652,"type":447,"marks":653}," For e-commerce, there's no store signage or friendly associate to ask for guidance. The unboxing itself is the entire physical experience from a brand. Gen Z is the first generation to change buying behavior when they perceive waste, which makes packaging a churn risk, not just a cost line.",[654],{"type":575,"attrs":655},{"color":577},{"type":443,"attrs":657,"content":658},{"textAlign":457},[659,664,672],{"text":660,"type":447,"marks":661},"Layer automation on top, and the picture gets sharper. ",[662],{"type":575,"attrs":663},{"color":577},{"text":265,"type":447,"marks":665},[666,670],{"type":629,"attrs":667},{"href":263,"uuid":668,"anchor":457,"custom":669,"target":634,"linktype":28},"7a9026dd-8835-4e0c-aacc-82e7c01c24e0",{},{"type":575,"attrs":671},{"color":577},{"text":673,"type":447,"marks":674}," and goods-to-person systems have largely improved the picking bottleneck. However, the bottleneck has simply moved downstream to packout. The common fix of adding more pack stations quietly erodes the labor-savings return on investment (ROI) that justified the automation investment in the first place, and it amplifies every inefficiency already built into how orders get packed.",[675],{"type":575,"attrs":676},{"color":577},{"type":579,"attrs":678,"content":679},{"level":581,"textAlign":457},[680],{"text":681,"type":447,"marks":682},"Where Basic Cartonization Falls Short",[683,685],{"type":575,"attrs":684},{"color":577},{"type":605},{"type":443,"attrs":687,"content":688},{"textAlign":457},[689,694,701,706,716],{"text":690,"type":447,"marks":691},"Most operations already have ",[692],{"type":575,"attrs":693},{"color":577},{"text":695,"type":447,"marks":696},"some",[697,699],{"type":575,"attrs":698},{"color":577},{"type":700},"italic",{"text":702,"type":447,"marks":703}," ",[704],{"type":575,"attrs":705},{"color":577},{"text":707,"type":447,"marks":708},"cartonization",[709,714],{"type":629,"attrs":710},{"href":711,"uuid":712,"anchor":457,"custom":713,"target":634,"linktype":28},"/posts/what-is-cartonization","e6c3d89d-7db7-41ee-a16e-af0f491dd3da",{},{"type":575,"attrs":715},{"color":577},{"text":717,"type":447,"marks":718},", the logic in the order process where a box and packing instructions are determined for a given shipment. But as a bolt-on feature, it hasn't kept pace with how important packout has become. It tends to be inflexible, and by default it optimizes for the smallest box, not the lowest actual cost.",[719],{"type":575,"attrs":720},{"color":577},{"type":443,"attrs":722,"content":723},{"textAlign":457},[724],{"text":725,"type":447,"marks":726},"When a category of fragile goods starts arriving damaged, the answer is usually a bunch of workarounds that pile up into an ongoing packaging challenge: rigid, expensive to unwind, and invisible to anyone outside the pack station.",[727],{"type":575,"attrs":728},{"color":577},{"type":579,"attrs":730,"content":731},{"level":581,"textAlign":457},[732],{"text":733,"type":447,"marks":734},"Where a Packing Control System Steps In",[735,737],{"type":575,"attrs":736},{"color":577},{"type":605},{"type":443,"attrs":739,"content":740},{"textAlign":457},[741],{"text":742,"type":447,"marks":743},"“Over a decade of doing this, I have not had one meeting with an operations leader where they had a true understanding of what was happening at packout.”",[744],{"type":575,"attrs":745},{"color":577},{"type":443,"attrs":747,"content":748},{"textAlign":457},[749,758],{"text":750,"type":447,"marks":751},"James Malley",[752,756],{"type":629,"attrs":753},{"href":754,"uuid":457,"anchor":457,"custom":755,"target":634,"linktype":141},"https://www.linkedin.com/in/jmalley/",{},{"type":575,"attrs":757},{"color":577},{"text":759,"type":447,"marks":760},", Co-Founder and CEO, Paccurate",[761],{"type":575,"attrs":762},{"color":577},{"type":443,"attrs":764,"content":765},{"textAlign":457},[766],{"text":767,"type":447,"marks":768},"Across every team we've talked to that's solved this problem, the same capabilities show up:",[769],{"type":575,"attrs":770},{"color":577},{"type":772,"content":773},"bullet_list",[774,791,807],{"type":775,"content":776},"list_item",[777],{"type":443,"attrs":778,"content":779},{"textAlign":457},[780,786],{"text":781,"type":447,"marks":782},"Execution.",[783,785],{"type":575,"attrs":784},{"color":577},{"type":605},{"text":787,"type":447,"marks":788}," Fast, 3D-aware cartonization that accounts for real costs such as negotiated carrier rates, materials, and labor, and routes decisions intelligently, whether that's to a box, a mailer, or an automated packaging machine.",[789],{"type":575,"attrs":790},{"color":577},{"type":775,"content":792},[793],{"type":443,"attrs":794,"content":795},{"textAlign":457},[796,802],{"text":797,"type":447,"marks":798},"Flexibility.",[799,801],{"type":575,"attrs":800},{"color":577},{"type":605},{"text":803,"type":447,"marks":804}," The ability to change packing rules when the business changes, without waiting on an IT roadmap. A new fragile SKU category shouldn't require a code deployment to fix.",[805],{"type":575,"attrs":806},{"color":577},{"type":775,"content":808},[809],{"type":443,"attrs":810,"content":811},{"textAlign":457},[812,818],{"text":813,"type":447,"marks":814},"Monitoring.",[815,817],{"type":575,"attrs":816},{"color":577},{"type":605},{"text":819,"type":447,"marks":820}," Real visibility into what's actually happening at packout before the CFO calls about the balance sheet, or a packer quietly abandons the SOP because it doesn't hold up in practice.",[821],{"type":575,"attrs":822},{"color":577},{"type":443,"attrs":824,"content":825},{"textAlign":457},[826],{"text":827,"type":447,"marks":828},"Data accuracy is a requirement for optimizing packing control. Effective cartonization needs dimensional data which includes item length, width, height, and weight. With dimensioning hardware more available and more affordable, this information is dramatically easier to collect. Artificial Intelligence's (AI) rise has made it easier to get budget approved for data initiatives, which used to be a hard sell.",[829],{"type":575,"attrs":830},{"color":577},{"type":579,"attrs":832,"content":833},{"level":581,"textAlign":457},[834],{"text":835,"type":447,"marks":836},"Two Different Problems, Same Solution",[837,839],{"type":575,"attrs":838},{"color":577},{"type":605},{"type":443,"attrs":841,"content":842},{"textAlign":457},[843,854],{"text":844,"type":447,"marks":845},"Altitude Sports",[846,851,853],{"type":629,"attrs":847},{"href":848,"uuid":849,"anchor":457,"custom":850,"target":634,"linktype":28},"/case-studies/altitude-sports-case-study","784993d6-287e-43ed-be3d-b2f37fbbfca1",{},{"type":575,"attrs":852},{"color":577},{"type":605},{"text":855,"type":447,"marks":856}," dealt with SKU complexity and high labor turnover, training packers on a wide product mix was slow and inconsistent. Therefore, giving packers a system they could trust to recommend the right packaging removed the guesswork entirely.",[857],{"type":575,"attrs":858},{"color":577},{"type":443,"attrs":860,"content":861},{"textAlign":457},[862,873],{"text":863,"type":447,"marks":864},"Daily Harvest",[865,870,872],{"type":629,"attrs":866},{"href":867,"uuid":868,"anchor":457,"custom":869,"target":634,"linktype":28},"/case-studies/from-sustainably-sourced-to-sustainably-shipped-daily-harvest-optimizes-packing","588a8ea5-2162-4c97-9f68-e2dda1f10254",{},{"type":575,"attrs":871},{"color":577},{"type":605},{"text":874,"type":447,"marks":875}," faced a different challenge as a cold-chain, direct-to-consumer brand: getting every order packed with the right coolant, every time. The stakes were higher. A broken item is bad, a spoiled one is worse. A dedicated packaging strategy solved for that consistency at scale.",[876],{"type":575,"attrs":877},{"color":577},{"type":579,"attrs":879,"content":880},{"level":581,"textAlign":457},[881],{"text":882,"type":447,"marks":883},"The Case for ROI",[884,886],{"type":575,"attrs":885},{"color":577},{"type":605},{"type":443,"attrs":888,"content":889},{"textAlign":457},[890],{"text":891,"type":447,"marks":892},"The return shows up in more places than most teams expect:",[893],{"type":575,"attrs":894},{"color":577},{"type":772,"content":896},[897,925,941],{"type":775,"content":898},[899],{"type":443,"attrs":900,"content":901},{"textAlign":457},[902,908,913,920],{"text":903,"type":447,"marks":904},"Automation ROI.",[905,907],{"type":575,"attrs":906},{"color":577},{"type":605},{"text":909,"type":447,"marks":910}," Pairing an AMR deployment with Paccurate’s 3D cube, cost-aware cartonization engine, ",[911],{"type":575,"attrs":912},{"color":577},{"text":38,"type":447,"marks":914},[915,918],{"type":629,"attrs":916},{"href":232,"uuid":36,"anchor":457,"custom":917,"target":634,"linktype":28},{},{"type":575,"attrs":919},{"color":577},{"text":921,"type":447,"marks":922},", has driven a 30–50% increase in ROI on the automation investment itself because getting more onto each shelf, each bin, each shipment compounds the value of the robot.",[923],{"type":575,"attrs":924},{"color":577},{"type":775,"content":926},[927],{"type":443,"attrs":928,"content":929},{"textAlign":457},[930,936],{"text":931,"type":447,"marks":932},"Throughput.",[933,935],{"type":575,"attrs":934},{"color":577},{"type":605},{"text":937,"type":447,"marks":938}," Repacks happen more often than most operations realize, whether from poor box selection or cartonization logic too simple to handle complex geometries. Fixing that is a direct throughput gain.",[939],{"type":575,"attrs":940},{"color":577},{"type":775,"content":942},[943],{"type":443,"attrs":944,"content":945},{"textAlign":457},[946,952],{"text":947,"type":447,"marks":948},"Sustainability that also saves money.",[949,951],{"type":575,"attrs":950},{"color":577},{"type":605},{"text":953,"type":447,"marks":954}," A 20% reduction in average box size can mean 20% fewer trucks on the road in floor-loaded trailers. It's one of the few sustainability initiatives that doesn't require a difficult pitch because the savings and the environmental case point in the same direction.",[955],{"type":575,"attrs":956},{"color":577},{"type":579,"attrs":958,"content":959},{"level":581,"textAlign":457},[960],{"text":961,"type":447,"marks":962},"The Real Question to Ask",[963,965],{"type":575,"attrs":964},{"color":577},{"type":605},{"type":443,"attrs":967,"content":968},{"textAlign":457},[969],{"text":970,"type":447,"marks":971},"Think about the last time your team needed to fix a packaging problem such as a fragile item showing up damaged or the finance team flagging dimensional weight charges. Was it a quick change, or did it need a committee?",[972],{"type":575,"attrs":973},{"color":577},{"type":443,"attrs":975,"content":976},{"textAlign":457},[977,982,989],{"text":978,"type":447,"marks":979},"If the answer is a committee, that's the case for a ",[980],{"type":575,"attrs":981},{"color":577},{"text":31,"type":447,"marks":983},[984,987],{"type":629,"attrs":985},{"href":226,"uuid":27,"anchor":457,"custom":986,"target":634,"linktype":28},{},{"type":575,"attrs":988},{"color":577},{"text":990,"type":447,"marks":991},". Packing has become the bottleneck of the fulfillment operation. Automating picking has only shifted the challenge downstream. Packaging touches everything in fulfillment and connects to transportation cost, compliance, customer experience, and automation ROI all at once. So, teams that treat it as a strategic system, not a WMS feature, are the ones who will control those costs instead of reacting to them.",[992],{"type":575,"attrs":993},{"color":577},"2026-10-16 00:00",{"_uid":996,"text":997,"links":1005,"headline":1010,"component":455},"cbf5adcf-e775-4341-aedb-44303e1356ba",{"type":440,"attrs":998,"content":999},{"backgroundColor":457},[1000],{"type":443,"attrs":1001,"content":1002},{"textAlign":457},[1003],{"text":1004,"type":447},"We can show you what a Packing Control System can do in your operation.",[1006],{"_uid":1007,"link":1008,"text":1009,"variant":452,"hasArrow":297,"component":453},"56c032ec-5059-4884-87ad-95883deedf2f",{"id":212,"url":13,"linktype":28,"fieldtype":29,"cached_url":213},"Book a demo","Ready for better packing control?","page","why-this-is-the-year-packing-gets-its-own-control-system","posts/why-this-is-the-year-packing-gets-its-own-control-system",-570,[],44289634,"43cbfc88-c2f0-49fb-9efd-e4ae3e9d2503",[],[],[],{"cache-control":470,"connection":471,"content-encoding":472,"content-type":473,"date":1022,"etag":1023,"referrer-policy":476,"sb-be-version":477,"server":478,"strict-transport-security":479,"transfer-encoding":480,"vary":481,"via":482,"x-amz-cf-id":1024,"x-amz-cf-pop":484,"x-cache":485,"x-content-type-options":486,"x-frame-options":487,"x-permitted-cross-domain-policies":488,"x-request-id":1025,"x-runtime":1026,"x-xss-protection":491},"Fri, 16 Oct 2026 20:51:04 GMT","W/\"c80768760a68c57f8f758a0be01877b6\"","0kd7O_PtljweNWliFNGPB-xm5ZUMhYuLNjX4r7qvv17VCgyFnTrMDg==","869d57e9-9567-47a6-9140-921ffbd4a934","0.031006",1792183862703]