The Basics: You’re Paying for the Whole Ride
Cape Pack makes the math simple.
Feed in your product dimensions, set your parameters, and within seconds it runs through thousands of possibilities to find the most efficient case and pallet designs.
Think of it like Tetris, where you’re using every bit of space that you possibly can,” Karl explained. “Everybody knows what Tetris is—I’ve got to fill this space. If I don’t, it’s wasted.”
Small Changes, Big Savings
Optimization might sound abstract, but the results are anything but. Let’s look at some examples of how companies have made small changes and achieved big results.
- Beer cans were reshaped to be taller and slimmer so more could fit on pallets.
- Dish soap bottles went from tall and skinny to shorter and squatter, cutting wasted headspace.
- And perhaps the best example: A large food corporation Karl recalled. “They saved millions of dollars in the first year—plus gallons of fuel—just from that one change.”
Regulations Are Catching Up
It’s not just about savings anymore.
The European Parliament recently adopted rules requiring transport, grouped, and e-commerce packaging to be no more than 50% empty space by 2030.
As Susie Stitzel, Director of Product Management at Esko, pointed out, “In Europe they passed a regulation that goes into effect in 2030… customers are already asking us how much air is in there.”
But some industry voices warn the mandate could backfire. Shipping damage could increase, or companies might lean toward more rigid materials to comply.
That’s where Cape’s Compression Strength analysis comes in. It helps companies design cases that not only meet the 50% rule but are strong enough to protect goods in transit.
In other words: Cape Pack doesn’t just help you pack tighter. It also helps you pack smarter and balance efficiency with durability.
Footprint vs. Cube (Made Simple)
When it comes to pallets, two terms come up a lot: footprint and cube utilization.
- Footprint = the 2D pallet base.
- Cube = the 3D height and volume.
“The footprint is much more important,” Karl said, noting that even an inch or two wasted around a pallet adds up across global shipments.
Better Collaboration Through 3D
Cape Pack also helps teams stay aligned. With CAD integration, the exact case file can be shared with corrugated manufacturers, ensuring the boxes are built right the first time.
And 3D modeling makes collaboration even easier. “Instead of saying ‘this is a cylinder four inches around,’ you actually have the real object itself,” Stitzel said. “It makes communication digital, clear, and accurate.”
Hidden Wins You Wouldn’t Spot Alone
Not everything fits neatly like tissue boxes. For trapezoids, cylinders, or yogurt tubs, Cape’s 3D smarts help companies uncover hidden efficiencies.
With trapezoids or cylinders, you can alternate them—like stacking cups in your cupboard—so you’re not wasting empty space.
Real-World Payoffs
The impacts add up quickly:
- Fewer pallets and trucks → lower costs.
- Less fuel → smaller carbon footprint.
- Automation-ready → Cape’s data even drives robotic stackers.
- Shipping more in less space → increased savings for both packaging and logistics.
And here’s a cool twist: Cape Pack’s data isn’t just for people with clipboards and calculators. It actually drives robotic pallet stackers too.
Our partner Robotiq takes Cape’s XML data — basically the exact coordinates of every box — and feeds it straight into their system. The robot then stacks cases automatically, exactly as Cape planned it.
No guesswork, no manual re-stacking, just precision.
It’s a great example of how optimization isn’t only about saving space. It’s also about making operations smoother, faster, and a lot less labor-intensive.
Cape Pack in Plain English
If you had to sum it up, Cape Pack is like Tetris for your supply chain—except now it also shows you the carbon footprint of every choice.
As Karl said, “We’re giving the designer with Cape Pack every bit of information we possibly can to enable them to design efficiently, sustainably, and economically.”
Cape has been refining these algorithms for over 60 years, so the math behind the optimization is tried, tested, and trusted.
Stop Shipping Air
At the end of the day, optimization is about making every inch count. With Cape Pack, companies get the tools to save more space and cut down on carbon.
Because really, who wants to pay to move around a bunch of empty boxes?
Stop shipping air. See Cape Pack in action with a free trial.
