Should I ship a customer's order in one large box or split it into two smaller ones?
Run both options in the calculator and compare the total chargeable weight: once for the large box, and once for the small box with a quantity of 2. Splitting only saves when it removes empty space from the big box, and even then your carrier may charge per piece with a fee or a minimum, which the tool does not know about.
Example: a 12 kg order
A customer order weighs 12 kg in total with packing, and you stock two carton sizes. With 5000 as an example divisor:
- Option one, a single 60 × 40 × 40 cm carton at 12 kg: volume 96,000 cm³ and a chargeable weight of 19.2 kg.
- Option two, two 40 × 30 × 30 cm cartons at 6 kg each: 7.2 kg per carton and 14.4 kg in total.
- The actual weight is 12 kg either way. The whole difference comes from volume: 96,000 cm³ against 72,000 cm³ for the pair.
In this case splitting saves 4.8 kg of chargeable weight, because the two small cartons hug the goods with less empty space. If the big carton were packed full, though, you would see little or no difference, and splitting could even cost more.
Working out both options
- In the Volumetric shipping-weight calculator, enter the large carton and its expected packed weight, and note the result.
- Change the dimensions to the small carton, the weight to one carton's weight, and type 2 in Identical packages.
- If the two boxes differ in size or weight, run each one separately and add the results.
- Compare the total chargeable weights, then look up the price for each on your carrier's table.
What the comparison does not show
- Per-piece charges: some carriers add a flat fee per parcel, or a minimum weight per piece. Two parcels can cost more than one despite the lower weight.
- The customer's experience: an order in two parcels may arrive on two different days, and a customer holding half an order tends to worry.
- Packing and time: two cartons mean more materials, labels and handling.
A working rule
If the large carton would have space you fill with padding, splitting or a middle size is likely to save. If it is packed full, stay with one box. Either way, make the check a habit before large orders, build the final shipping cost into your price with the Selling-price calculator, and split the contents across cartons on a packing list with the Packing-list generator so the customer knows what is in each parcel.
Common questions
Does the tool know my carrier's per-piece fees?
No. It calculates weights only and knows no prices or fees.
Could a third size beat both options?
Yes. Try any size you have in stock; each check takes seconds.
Does the actual weight change when I split?
It rises a little with the extra carton and padding, so enter each carton's packed weight.