Smart Packaging

TimberCloud's intelligent packaging algorithm analyzes your products and automatically determines the optimal way to package them for shipping.

How It Works

When you request shipping rates, the system:

1. Extracts Products - Reads dimensions, weight, and shipping configuration from each line item
2. Handles Parts - If products have parts configured, each part is extracted separately when Ships Assembled is OFF
3. Groups by Dimensions - Similar-sized items are grouped for efficient packing
4. Determines Package Type - Each item is assigned to Box or Pallet based on size and weight
5. Separates Hazmat - Hazardous materials are always packaged separately (required by law)
6. Applies Bin Packing - Uses 3D bin packing to fit items into fewest possible packages
7. Consolidates - Applies your consolidation rules (e.g., convert to pallet if > X boxes)

Example

ORDER: 10 cabinet doors + 5 drawer fronts + 2 hardware kits

BEFORE (No Optimization):  17 separate packages → $136 shipping
AFTER (Smart Packaging):   2 optimized packages → $48 shipping

SAVINGS: 65% ✓

Package Type Determination

The algorithm uses UPS/FedEx parcel shipping limits to determine package types:

Girth = 2 × width + 2 × height

Assembled vs Unassembled Products

Products can ship in two modes:

Assembled (Default)

• Product ships as a single unit
• Dimensions from line item or product defaults
• Weight from product configuration

Unassembled (Parts)

• Product ships as separate components
• Each part is packaged individually
• Parts can be consolidated or packaged separately based on configuration

Ships Assembled Toggle

This critical setting on your products determines how they ship:

The Packaging Algorithm

Step-by-Step Process

1. EXTRACT PRODUCTS
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   Read dimensions and weight from each order item
   If products have parts config, extract each part
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2. VALIDATE DIMENSIONS
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   Ensure all products have valid measurements
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3. GROUP BY DIMENSIONS
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   Similar items grouped for efficient packing
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4. DETERMINE PACKAGE TYPE
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   Check parcel limits:
   - Max dimension: 108"
   - Length + girth: 165"
   - Max weight: 150 lbs
   ↓
   Assign: Box or Pallet
   ↓
5. SEPARATE HAZMAT
   ↓
   Hazardous items in separate packages (required)
   ↓
6. BIN PACKING
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   Boxes: Fit items into optimal box sizes
   Pallets: Calculate stacking and layer placement
   ↓
7. APPLY CONSOLIDATION
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   If boxes > max_boxes_before_pallet:
   Reconsolidate everything to pallets
   ↓
8. RETURN PACKAGES
   ↓
   Optimized package list for rate shopping

Real-World Example

Order: 12 cabinet doors (24" × 36" × 1.5", 15 lbs each)

Step 1: Extract → 12 door items
Step 2: Validate → All dimensions valid
Step 3: Group → All same size, single group
Step 4: Package Type → Parcel-shippable (under limits)
Step 5: Hazmat → None
Step 6: Bin Pack → Fit 4 doors per "Long Large 48" box × 3 boxes
Step 7: Consolidation → max_boxes_before_pallet = 6, so keep as boxes

RESULT: 3 boxes, 4 doors each

Same order with consolidation = 2:

Step 7: Consolidation → 3 boxes > 2 threshold
        → Reconsolidate to 1 pallet (48×40", stack height 24")

RESULT: 1 pallet

Box Sizes

Default Box Sizes

When custom boxes are not configured, the system uses standard sizes:

Custom Box Sizes

Define boxes that match your actual packaging inventory. See Configuration for setup instructions.

Pallet Configuration

Default Pallet Specs

Common Pallet Sizes

Package Preview & Editing

Before fetching rates, you'll see automatically calculated packages:

• Type: Box or Pallet
• Dimensions: Width × Length × Height
• Weight: Calculated from products
• Freight Class: For LTL shipments
• Quantity: Number of identical packages

Edit Packages Manually

Click "Edit Packages" to:

• Adjust dimensions
• Change weights
• Add or remove packages
• Convert boxes to pallets
• Consolidate multiple boxes

Best Practices

1. Set Accurate Dimensions - Measure real products including packaging
2. Configure Freight Classes - Essential for LTL rate accuracy
3. Use Custom Box Sizes - Match your actual packaging inventory
4. Enable Consolidation - Set max_boxes_before_pallet for bulk orders
5. Test With Real Orders - Verify calculations match actual shipments
6. Leverage Auto Mode - Let the algorithm optimize carrier selection

Troubleshooting

Incorrect Package Calculation

• Verify product dimensions are set
• Check parts configuration if using unassembled shipping
• Review freight class settings
• Test with manual package editing

Everything Going to Pallets

• Check product dimensions aren't exceeding parcel limits
• Verify packaging_mode isn't set to "Pallets Only"
• Review individual product package_type settings

Too Many Boxes Generated

• Enable "Prefer Fewer Packages" in settings
• Lower the max_boxes_before_pallet threshold
• Add larger custom box sizes

Next Steps

• Rate Shopping - Compare carrier rates
• Configuration - Customize packaging settings
• Shipping Options - Product-level shipping settings
• Parts - Configure product components