How We Do It

 10 Steps to Actualization 

At BCI Global we have the real-world experience to craft a solutionthat will understand the flow of goods within your distribution network
and the steps that it will take to get your product from manufacturing to the retail shelf. We combine this expertise with proven analytics and field tested models to build an Actualization program that will:

  • Engage in a comprehensive study of your unique supply chain network to understand the “current state” 
  • Discover the true costs of your supply chain packaging and functions
  • Design nondisruptive Actualization strategies that will build a system of predictable and repeatable outputs and consistently yield better than expected savings

DESIGNATE a project team

COLLECT relevant data

AUDIT existing product handling and limitations

MEASURE current packaging performance

UNDERSTAND impacts of customer documentation

EVALUATE end-to-end processes and requirements

BENCHMARK supply-chain efficiencies

ENGINEER supply-chain and carton solutions

IDENTIFY and evaluate improvements and ROI

IMPLEMENT solutions and monitor savings

Sample Approach to
Potential Savings


  • Vendors sourced own packaging

  • Carton sizes not optimized for supply chain or product type.

  • Vendor sourced packaging did not match product footprints from all factories which lead to excessive empty space in shipping cartons. 

  • Real packaging costs were unknown to the brand. 

  • Inferior carton materials lead to poor carton performance and product damage.

  • Analyzed current packaging and supply chain processes.

  • Identified and measured constraints.

  • Performed a product mini study and freight analysis. 

  • Quantified the costs of the
    current process and the effects on transportation. 

  • Identified a list of optimal
    carton footprints.

  • Validated the savings of the
    optimized solution.

  • Standardized carton dimensions in unique product footprints to maximize space inside of the shipping cartons.

  • Increased product density and unit CBM per carton. 

  • Provided optimal packaging
    configurations for all product types and styles with shared footprints across all products. 

  • Implemented hands on factory training to ensure program integrity and packaging compliance.

Sample Results

Packing Methodology

Having control over your packing functions and costs can be elusive. Our years of experience across many industries and Fortune 500 companies have allowed us to innovate successful packaging models for all types of products and with varying degrees of packaging requirements. Our Actualization process is mathematically engineered to give you the exact space saving models and transportation savings that you can expect to get. 

The example (to the right) represents a real-life analysis of a soft good product that was used in one of our Actualization studies. The results are typical of the savings we bring to our customers:

  • Packaging cost per unit decreased by 8.7%
  • Sellable units shipped per cubic meter increased by 42.4%
  • The ocean freight cost per sellable unit (in outer carton) decreased by 17.9%
Press to Enlarge Statistics ------ > 

  Finding your hidden cost savings 

Inefficient packing procedures result in a poor use of space. This translates into lost opportunities for cost savings starting from the purchase of the carton to the shipping container to warehousing and distribution.

Sample Unit

               Sample Unit               

Simple product, like a pair of casual pants, has the opportunity to use space more efficiently (per the calculations, above).

Previous Product Packing

      Previous Product Packing     

The relationship of a carton's outer space to its available internal packing space, when combined with the role of a carton's footprint (Length x Width x Height), are often overlooked and can cost companies millions of dollars.

Re-Engineered Product Packing

  Re-Engineered Product Packing 

By calculating the proper footprint and accounting for all supply-chain processes, a carton with virtually identical cubic size increased products per unit of space by over 40% resulting in significant transportation and storage savings.