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How would you decide whether to redesign packaging for air freight?

If a product's chargeable weight is much higher than its actual weight, what would you test before changing the carton?

7 replies

  1. Measure the final packed dimensions first. It's hard to improve a cost model built from catalog dimensions rather than the carton that actually ships.
  2. Ask packaging and quality staff what protection is necessary. A smaller box is not a saving if damage and returns increase.
  3. Try a small validated packaging trial and compare the total outcome. Include labor, material and damage risk alongside freight. A new carton might save space but take longer to pack, need a different insert or be harder for the customer to handle. Agree on the acceptance criteria with quality first, then use the trial to see whether the proposed saving survives the real packing process.
  4. Check whether palletization changes the result. Efficient individual cartons can still create wasted space once the shipment is built.
  5. If the goods are regulated or contain batteries, involve the dangerous-goods specialist before modifying the pack. Freight efficiency doesn't override packaging requirements.
  6. Keep the approved packaging specification available to the supplier. Otherwise the optimized version may quietly revert during a busy production run.
  7. Ask the forwarder to quote the proposed pack before rolling it out. A dimensional improvement on paper may not change the actual rate break or minimum charge.

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