Issue #002 — Pack density that doesn’t break compliance

More units per container = lower landed cost if you don’t trip testing, labeling, or damage rates.

The Density Ladder. (1) inner-pack changes → (2) master carton → (3) pallet pattern → (4) component nesting. Move one rung at a time and re-measure CBM/unit.

Compliance gates. Keep required labels/instructions, suffocation holes/vents, and regulatory clearances (CPSIA, FDA/food-contact, Prop 65, REACH/CE/UKCA).

ISTA matters. For fragile goods, run ISTA 3A (or relevant) after any density change. Damage > target? Roll back or add low-cost protections.

Common wins. Thinner but stronger cartons; rotate components; reduce void fill with die-cuts; switch from 6-pack to 4-pack if it raises units/40HC net of damage.

What to document. New dims/weight/CBM, photos, test results, and updated inbound cost per unit.

Do this week:

• Re-weigh and re-measure your current CBM/unit.

• Prototype one inner-pack change; project units/40HC and damage risk.

• If risk is non-trivial, queue a lab check (ISTA / drop / compression).

Want a density quick-win list for your SKU? Book a GM Teardown →