Outcome we drive: smaller cubes and stronger packs—so you pay less for freight and still pass every drop, shock, and stack test.
How IndiaUnbox cuts your freight bill (with math, not guesswork)
- Right-size cartons to reduce chargeable weight (air): Air freight bills the higher of actual vs. volumetric weight. The industry rule-of-thumb is L×W×H (cm) ÷ 6000; some carriers use other divisors (e.g., 5000). We design cartons to beat the divisor—without hurting protection.
- Shrink CBM for LCL/ocean: LCL charges by 1 CBM or 1000 kg (whichever is higher); trimming height/voids directly lowers your freight ton.
- Optimise pallet & container fit: We engineer case sizes to nest on ISO pallet footprints (1200×1000 mm, 1200×800 mm) and pack to real container internals (e.g., 40′ HC ~12.03 m × 2.35 m × 2.70 m), improving cube utilisation and stack stability.
A quick numbers example
- Current master carton: 62×42×38 cm = 98,952 cm³ → 16.49 kg chargeable weight at 6000 divisor.
- After design trim (same protection): 62×42×33 cm = 85,932 cm³ → 14.32 kg chargeable.
- Savings: 2.17 kg/carton on air freight; at $3.50/kg, that’s $7.60/carton. On ocean LCL, you save 0.013 m³/carton; 100 cartons save 1.30 m³ (e.g., $80/CBM ⇒ $104 saved).
How we protect products while shrinking cartons
- Standards-led transit testing:
– ISTA 3A for parcel/express shipments (vibration + drop, with an optional low-pressure segment).
– ASTM D4169 distribution cycles for palletised loads and freight systems (sequential hazard testing at representative levels). - BIS-grade corrugated specs: We set board grade and construction to India’s latest IS 2771 (Part 1) for corrugated fibreboard boxes, so cartons meet codified burst/edge and workmanship requirements.
- Stacking & compression logic: Case design and flute selection target container/pallet stacks within a 40′ HC height and door opening limits (door height typically less than internal), so “theory” fits actually load.
- Hazardous or regulated goods: Where applicable, we align packaging with Indian Guidelines for Transportation of Dangerous Goods and storage/marking rules.
What we actually change in your packaging
- Carton geometry: Reduce empty headspace; move from single to tray + lid or RSC with fit-to-product inserts; compressible cushioning where ISTA/ASTM allows.
- Pallet patterns: Re-pattern to ISO footprints (1200×1000 / 1200×800) for tighter container fills and better load plans (turning mixed-SKU “air pockets” into shipped product).
- Materials mix: Switch to correct ECT/burst class per BIS 2771 and product weight; introduce die-cut braces, edge protectors, and cross-banding to keep stacks from leaning under vibration.
- Moisture & handling: Add liners/desiccants where routes are humid; print handling marks and CLP/UN marks when required for dangerous goods.
How we prove it (before you ship)
- Should-cost & should-cube: We model freight using your lanes: air divisor (e.g., 6000), or LCL 1 CBM = 1000 kg rule, plus planned palletisation.
- Prototype & lab test: Build trial packs → run ISTA 3A/ASTM D4169 as relevant to your channel.
- Load plan validation: Fit test against 40′ HC or chosen container, considering door opening and safe stack heights.
- Spec & SOP lock: Freeze drawings, packing specs (BIS 2771 reference), and inspection checklists for suppliers.
Your deliverables
- Packaging Spec Pack: carton & inner fitments, pallet patterns, labelling, and QC checkpoints—mapped to BIS 2771 / ISTA / ASTM where applicable.
- Freight Impact Sheet: old vs. new CBM/chargeable weight by SKU, with lane-specific examples (air divisor, LCL rule) so savings are audit-ready.
- Container Load Plan: drawings using ISO pallet sizes and 40′ HC internals/door openings to avoid last-minute surprises at stuffing.
Bottom line: IndiaUnbox blends engineering tests (ISTA/ASTM) with the billing math of air and ocean freight and Indian BIS standards—so your cartons get smaller, your shipments get cheaper, and your products still arrive perfect.
