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B to D Flute Savings Calculator

All Tools & Calculators Corrugated Optimization Tool  ·  B to D Flute

B to D Flute Soft Cost Savings Calculator

D flute ships ~25% more units per load than B flute. Quantify what that density improvement is worth across freight, storage, labor, dunnage, admin, and inventory carrying cost.

Delivered pricing note: Your freight cost is baked into your unit price. When D flute ships 25% more units per load, your supplier's inbound cost drops — that's an argument to bring back to your rep for a pricing conversation. The savings you control directly are captured below.
Inbound freight
loads / yr
$
Warehouse storage
sq ft
$/ sq ft / yr
Receiving & line feeding labor
hrs / load
$/ hr
shifts / yr
trips / shift
min / trip
Dunnage disposal & recycling
loads / yr
Slip sheets, corner boards, stretch wrap, and corrugate packaging broken down per load
min / load
$/ load
Dumpster pull share, baler cost, or hauling fee per load
Purchasing & admin time
POs / yr
min / PO
$/ hr
Inventory carrying cost
Not sure of your inventory value on hand? Use this helper.
$
weeks
Estimated inventory on hand: —
$
What's sitting in your warehouse right now — not your annual spend
% of inventory / yr
Typically 20–30%: cost of capital, obsolescence, insurance, handling

Estimated annual soft cost savings

~25% density improvement
Freight savings
$0
0 fewer loads / yr
Storage savings
$0
0 sq ft reclaimed
Labor savings
$0
0 hrs / yr recovered
Dunnage disposal
$0
0 fewer loads to break down
Purchasing admin
$0
0 fewer POs / yr
Inventory carrying
$0
less capital tied up
Estimated total annual soft cost savings
Storage + labor + dunnage + admin + inventory carrying
$0
Freight reduction—
Warehouse storage reclaimed—
Receiving labor (unloading)—
Line feeding labor—
Dunnage disposal & recycling—
Purchasing & admin time—
Inventory carrying cost reduction—
How this is calculated: D flute nests ~25% more efficiently than B flute, reducing inbound load frequency, warehouse footprint, line feeding touches, dunnage volume, and PO frequency by the same proportion. Inventory carrying cost reflects holding 25% less stock to maintain equivalent supply. Conservative estimates — actual results vary by application, line configuration, and supplier terms.

Want us to validate these numbers?

We'll review your specific application, line setup, and current B flute spec — and confirm whether D flute is the right move.

Talk to a packaging specialist →