Freight & Dimensional
Weight Optimization
You are shipping air. Carriers bill on whichever is greater — your product's actual weight, or the size of the box it went out in. For most D2C brands it is the box.
Box matrix, void fill, carrier terms and incoterms — priced per lane.
The DIM weight problem
Since 2015, all major carriers charge based on dimensional weight when it exceeds actual weight. Most D2C packaging was never optimized for this reality.
Oversized boxes
A small box matrix means most products ship in a box far bigger than they need. Carriers bill on whichever is greater — actual weight or dimensional weight — so you pay for the empty space.
DIM weight surcharges
DIM weight is (L x W x H) / DIM factor — 139 for UPS and FedEx domestic, 166 for USPS Priority. For a light product in a large box, that number is what you are billed on, not the scale weight.
Hidden freight markups
When freight is bundled into a supplier invoice you never see the underlying rate, so there is nothing to compare and nothing to negotiate. Separating it is the first step.
How we optimize freight costs
Four levers, in the order they usually pay off.
Box Right-Sizing
We analyse your full product catalogue and design a box matrix around it, so each product ships in a box sized for it rather than for the largest thing you sell.
Void Fill Reduction
Smaller boxes mean less void fill. We calculate the requirement for each box-product combination, which for a well-sized package is often none at all.
Carrier Negotiation
We benchmark your carrier rates and negotiate DIM factor, zone pricing and volume tiers. Most D2C brands are on a default rate card that was never negotiated.
Incoterms Optimization
Many brands accept supplier-dictated incoterms without pricing the alternative. We restructure them so freight responsibility sits where you can actually control the cost.
What the arithmetic looks like
Worked examples at a DIM factor of 139, not client results. Run your own on the calculator below.
12 x 10 x 8 in, 1.2 lb actual → 7 lb billed
8 x 6 x 4 in, 1.2 lb actual → 2 lb billed
14 x 12 x 6 in, 2.1 lb actual → 8 lb billed
10 x 8 x 4 in, 2.1 lb actual → 3 lb billed
18 x 14 x 10 in, 8 lb actual → 19 lb billed
16 x 12 x 8 in, 8 lb actual → 12 lb billed
Free DIM Weight Calculator
Calculate your current DIM weight charges and see how much you could save with right-sized packaging. Enter your box dimensions and product weight to get instant results.
Related resources
Stop paying to ship air
Run our free Margin Leak Scanner to see how much your packaging freight costs could drop with the right box sizes and carrier rates.
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