PACKAGING COST AUDIT TOOLS + INDEPENDENT ENGINEERING
Find the Packaging Costs Hiding in Every Shipment.
Most companies know what their box costs.
Far fewer know what their packaging system costs after freight, packing labor, damage, returns, rework, storage, and waste are included.
TH3BOX helps ecommerce brands and growing manufacturers measure those costs, identify the problems causing them, and decide what to fix first.
The Packaging Material Is Only One Part of the Cost.
A lower-cost box does not automatically create a lower-cost packaging system.
A packaging change can reduce material cost but increase product damage. A stronger box can cost more per unit but reduce returns. A smaller shipping package can reduce both material usage and dimensional freight charges. A simpler packout can improve labor efficiency even when the individual packaging component costs more.
TH3BOX tools help you evaluate packaging as a complete business system.
Materials
Boxes, mailers, inserts, bags, labels, tape, void fill, cushioning, and other packaging components.
Freight & Cube
Package dimensions, dimensional weight, billable weight, pallet density, storage space, and unused package volume.
Damage & Returns
Replacement product, reshipping, refunds, rework, customer service time, claims, and customer dissatisfaction.
Packing Labor
Box assembly, insert placement, product loading, void fill, sealing, labeling, inspection, and rework.
Inventory & Complexity
Packaging SKU count, minimum order quantities, warehouse space, stockouts, obsolete materials, and operator selection errors.
Start With the Level of Help You Need.
Solve It With Your Team
Use guided field guides, diagnostic worksheets, and working Excel calculators to measure packaging costs, investigate likely root causes, compare improvement scenarios, and build a financial business case.
The tools explain packaging terminology in plain language and guide your team through the process one step at a time.
Bring In a Packaging Engineer
Get direct support when the problem requires packaging design, specifications, testing, validation, supplier coordination, or implementation.
TH3BOX provides independent engineering recommendations based on your product, distribution system, operating requirements, and financial objectives.
The complete system for measuring packaging cost, diagnosing freight, damage, and labor problems, comparing proposed improvements, and building the financial case for action.
Best for:
Companies with multiple products, multiple packaging problems, or no established packaging improvement process.
Over $1,000 when purchased separately
What Packaging Problem Are You Trying to Solve?
Calculate the true cost of packaging across materials, freight, labor, damage, storage, waste, and operational complexity for up to 50 products or package configurations.
Best for:
Teams that know packaging costs are increasing but do not know where the money is going.
Calculate the financial impact of packaging damage, organize failure data, identify likely root causes, and determine how much packaging improvement may be financially justified.
Best for:
Products experiencing breakage, leakage, crushing, returns, reshipments, or recurring customer complaints.
Evaluate package size, dimensional weight, unused space, carrier quotes, pallet density, storage impact, and right-sizing scenarios.
Best for:
Companies shipping large boxes, excessive void fill, lightweight products, or high parcel volumes.
Measure labor cost per order, document packout steps, identify bottlenecks and rework, and compare current and proposed packing processes.
Best for:
Teams experiencing slow packing, process inconsistency, excess handling, or increasing fulfillment labor.
Turn a proposed packaging improvement into a low, expected, and high financial case using annual savings, implementation cost, ROI, payback, risk, and validation requirements.
Best for:
Teams that have identified a possible packaging improvement but need leadership approval.
THE COMPLETE SELF-GUIDED SYSTEM
Packaging Profit System
Find, quantify, and prioritize the packaging improvements worth acting on.
The Packaging Profit System combines five integrated toolkits into one complete packaging improvement system.
It helps your team establish the current cost of packaging, diagnose the areas causing the greatest financial loss, compare possible changes, and develop a defensible improvement plan before committing to a redesign.
Included:
Packaging Cost Audit System
Freight & Cube Savings Toolkit
Damage Reduction Diagnostic
Pack Process Efficiency Toolkit
Packaging Opportunity Business Case
Analysis for up to 50 products or packaging configurations
Low, expected, and high financial scenarios
Current-versus-proposed comparisons
Green, Yellow, and Red decision gates
Engineering review recommendations
Completed supplement-company example
Executive summaries for leadership review
Complete Single-Company System - $699
Move From a Packaging Concern to a Business Decision.
1. Measure
Document current packaging materials, dimensions, freight, labor, damage, waste, and annual volume.
2. Diagnose
Identify where money is being lost and separate visible symptoms from likely root causes.
3. Quantify
Calculate the financial impact of the current problem and the potential value of correcting it.
4. Prioritize
Rank opportunities using financial impact, implementation effort, confidence, risk, and validation requirements.
5. Decide
Determine whether the next step can be completed internally or requires engineering, testing, or regulatory review.
Know When to Proceed—and When to Stop.
Green
A lower-risk opportunity that may be appropriate for internal investigation or controlled implementation.
Yellow
A potential opportunity that requires additional information, a production trial, carrier validation, or package testing before implementation.
Red
Do not implement the change without packaging engineering, safety, regulatory, or testing support.
The tools do not pretend that a spreadsheet can approve a package design. They help your team determine what is financially important and what must be validated before making a change.
Start With a Tool. Upgrade to Expert Support Without Losing Your Investment.
Sometimes the audit identifies an opportunity your team can implement internally.
Other times, it reveals a problem that requires packaging engineering, testing, specifications, supplier coordination, or implementation support.
Apply 100% of the amount paid for an eligible TH3BOX tool toward one qualifying consulting engagement of at least $2,000 initiated within 90 days.
Independent Packaging Guidance for Companies Without an In-House Packaging Engineer.
TH3BOX was founded by Brett Delwiche, a packaging engineer with experience across medical device, automotive, industrial, and consumer-product packaging.
The goal is straightforward: give growing companies access to structured packaging analysis without requiring them to immediately commit to a large consulting project.
TH3BOX does not sell boxes, films, labels, or packaging equipment. Recommendations are based on the needs of the complete packaging and distribution system—not on selling more material.
Learn How to Find Packaging Cost Leaks.
Get practical packaging breakdowns, cost examples, damage-reduction strategies, and new product analyses delivered to your inbox.
FAQ
Are these tools only for packaging engineers?
No. The tools are designed so a non-technical operations manager, ecommerce founder, purchasing professional, or fulfillment leader can complete them. Packaging terms are explained in plain language.
How much data do I need?
Start with the information you already have. The strongest results come from package dimensions, weights, component costs, annual volume, freight information, packout time, and damage or return data. Missing data can also help show what your company needs to begin tracking.
Will the tools tell me the exact box or material to purchase?
No. The tools identify, quantify, and prioritize packaging opportunities. Exact material specifications, structural designs, supplier decisions, and validation requirements may require packaging engineering support.
Can I apply my purchase toward consulting?
Yes. One hundred percent of the amount paid for an eligible product may be applied toward one qualifying TH3BOX consulting engagement of at least $2,000 initiated within 90 days. Additional terms apply.
What if my product is regulated, hazardous, fragile, or safety-critical?
Use the tools to organize information and understand the financial issue, but do not implement packaging changes without appropriate engineering, regulatory, safety, and testing review.