Case study: cutting packaging from 3 boxes to 1, saving CAD $2.50–$2.70 per unit
The problem
Every pressure washer shipped through ShipBob was going out in three separate boxes. One for the pressure washer, one for the five accessories, and a third outer box just to hold the other two together.
Three boxes means three times the material, more dimensional weight, and freight costs that were higher than they needed to be on every single unit.
What we changed
We redesigned the packaging directly with the supplier in China, before it ever reached ShipBob. One custom box, built with an internal partition. One side holds the pressure washer securely; the other holds all five accessories.
No outer box needed anymore, because the single carton does what three used to do.
The result
Packaging went from 3 boxes to 1. That alone cut CAD $2.50 to $2.70 per unit, and dimensional weight dropped along with it, which brought freight costs down too.
This isn't a one-time saving. It's baked into every unit shipped from here forward, and the product is still just as secure in transit as it was in three boxes.
The takeaway
The fix wasn't at the warehouse. It was at the source, redesigning the box with the supplier before the product ever got packed the old way. Getting the packaging right upstream is what turned a recurring freight cost into a permanent saving on unit economics.