CASTN: Efficient Carton Set Optimization for Logistics and Retail

In online retail, trends and seasonal fluctuations are a constant challenge. They not only influence the item and order structure, but also require continuous adaptation of shipping cartons to meet changing requirements. However, we often see small products being shipped in oversized cartons, which is due to insufficient coordination between items and packaging. Although many companies have a wide range of box sizes to choose from, these are often not optimally matched to the various product sizes and weights. This leads to unnecessary empty space and wastes valuable resources, as vast amounts of cushioning material are used. The solution lies in efficiently matching cartons and products to make optimal use of space, i.e., reducing empty volume and saving packaging material.

The CASTN carton set optimization software determines a suitable selection of shipping cartons for each mail order company individually in order to maximize volume utilization within the cartons while minimizing the number of carton sizes required.

The item and order data as well as the currently used carton sizes are used to calculate a suitable standard carton set. After data cleansing, the current empty space ratio is first calculated and then optimized, i.e., a new standard carton set is determined. Customer-specific parameters can be taken into account, such as the maximum or minimum carton size, weight restrictions, or special cartons that must be included in the set in all cases.

Mail order companies can save up to 15-20% of their packaging and transport costs with CASTN. In addition, the EU Packaging and Packaging Waste Regulation (PPWR) has been in force since February 2025, which stipulates a reduction in packaging material and a maximum void ratio of 50% in shipping cartons in all EU countries from 2030. Since mail order companies are required to provide evidence of compliance, carton set optimization can both help them implement the regulation and serve as proof for the auditing authorities.

Courier, express, and parcel service providers benefit from optimally packed parcels because they can make better use of their vehicles and thus transport more efficiently. This means that more parcels can be delivered with the same number of trips.

As the volume of packaging increases, so does consumer awareness of the need for greater sustainability. This is reflected in a growing demand for environmentally friendly packaging solutions. In short, consumers want less packaging waste. CASTN makes this possible.

Optimize your shipping now with CASTN and calculate your new standard box set, which is individually tailored to your order and item structure.

CASTN Basic

The basic module enables a comprehensive analysis of your current box set with up to three status quo calculations. You receive detailed evaluations of the volume utilization rate, the consumption of individual box formats, the average number of boxes per order, and the total shipping volume, based on the uploaded master and order data. In addition, you can calculate up to three carton set optimizations based on your uploaded data. The optimization also takes into account individual specifications such as dimensions, permissible girth, or weight. Results and technical details for the individual cartons in the sets are available for download. 

CASTN Pro

CASTN Pro expands the basic functions to include the option of creating and analyzing up to three custom carton sets (Custom Carton Set). In the Pro version, you can also create a clear management summary that makes it easier to evaluate and document your results.

CASTN Expert

The Expert module is aimed at companies such as packaging manufacturers and shipping service providers who want to use CASTN as a service for their customers. In addition to all the functions of the “Basic” and “Pro” modules, advanced configuration options and individual customizations are available. The third-party module allows flexible use for different customers and projects, making it ideal for expanding your own service portfolio.

CASTN® IML

Would you like to have experts at your side to optimize your carton set? Then commission CASTN as part of a Fraunhofer project. You will benefit from customized data preprocessing and preparation, comprehensive status quo analyses, and expert optimization of your carton set. You will also receive final advice on the future composition of your box set. All services are performed personally by experienced CASTN developers. 

Interested? Get in contact!