Extended Case Calculation – maximum filling level packages and pallets

Calculation of the optimal packaging result

The topic of packaging planning has become increasingly important in the logistics sector in recent years. Optimally packaging goods for storage, internal material flow or shipping costs time and money. Optimized packaging is therefore a competitive advantage over competitors and can improve one's own position on the market.

Both in package and transport planning as well as in packaging in shipping, the following applies: reliable and optimal precalculation of the shipping units is the main goal of packaging planning here, so that customers can be guaranteed the smallest possible packaging and zero transport of "air" can be guaranteed.

Application areas

The pick-and-pack process is frequently used in the e-commerce sector. In this process, the goods are packed directly into the order package during picking. This eliminates subsequent packaging in shipping, which saves both time and money. With this concept, the size and contents of the shipping packages are already calculated in SAP EWM or SAP TM during production planning.

With traditional packaging methods, the shipping process can be very time-consuming and costly if many articles need to be dispatched. Again here, the suggestions generated during packaging planning can provide efficient support for your staff. To obtain an exact preview of the required cargo space for shipping or to implement either a system-based or fully automated palletising process, the calculated shipping units are re-planned as required in a second level of palletisation planning.

Using SAP EWM/TM Extended Case Calculation, all goods intended for storage, internal material flows or shipping can be optimally, cost-effectively and safely packed, palletised and shipped via guidance from the system.

By integrating a camera into the packaging process, the packages, their dimensions, position or orientation are recorded automatically. On the one hand, the master data is checked. On the other hand, the packing processes carried out on the basis of the packer's experience and know-how are taken into account for further packing proposals in the future. Recorded residual volumes are planned ad hoc for further articles.


Particularly in the e-commerce sector, in which there are typically only a few articles per shipping package, over-packaging errors can occur when using standard SAP EWM/TM packaging planning with water displacement. Despite volume reserves, it may be the case that the articles cannot be efficiently arranged in the shipping package due to their shape. This results in time-consuming repacking or flat-rate "shipping of air" by reducing the maximum volume for the calculation.


  • Overpacking errors despite volume reserves
  • The shape and arrangement of the goods are not taken into account when calculating with water displacement


  • Uses a simple stacking pattern algorithm
  • Optimal packing pattern and optimal use of packaging
  • Overpacking errors are eliminated
  • Maximum use of the remaining volume


  • Different calculation heuristics (water displacement, sizing pattern, etc.)
  • Visual representation of the packing result
  • Packing simulation as load preview or loading space preview
  • Camera-supported, automatic recording of packages, dimension / position / orientation, and automated confirmation of packing processes
  • Consideration of influencing parameters, such as the inventory situation, warehouse topology, packing prohibitions as well as sequencing rules
  • Consideration of article characteristics and customer- or carrier-specific packing materials and restrictions (e.g. max. pallet height)
  • Highly effective packing algorithm, developed together with the Fraunhofer Institute, further self-learning when used in the camera-based packing process

Key Facts

  • Collaborative packing assistance system saves up to 30 percent shipping volume
  • Detection of master data deviations based on camera data
  • Self-learning scheduling algorithm optimizes itself by know-how and experience of the packer
  • "Adhoc scheduling" of the remaining volume determined by the camera for maximum utilization of the packing space
  • Intuitive 3D pick / pack instruction
  • Reduction of transport / shipping shipping costs


The reliable and optimal pre-calculation of the shipping unit is the main objective of the packaging planning, so that the customer can be guaranteed the smallest possible packaging and no transporter of "air".

Johannes Zeitler, Sales SAP TM Solutions