Fraunhofer SCAI has added planning for pallet and truck loading, as well as cost calculation, to its PackAssistant packaging software. The new version extends packaging planning to include additional stages of the transport chain. Companies can now compare multiple solutions in terms of their packing and logistics costs.

The software’s core function remains the space-efficient arrangement of identical parts in containers. Its 3D packaging planning is based on CAD data and takes into account not only a part’s length, width, and height, but also its actual geometry. PackAssistant uses this information to calculate arrangements that make the best possible use of available space while also protecting parts from damage. For parts with complex shapes in particular, these calculations can reduce or eliminate time-consuming manual packing trials. This allows packaging solutions to be evaluated as early as the product development stage.

The new features build on this container load optimization. Once the arrangement of the parts has been determined, PackAssistant places the loaded containers on pallets and then arranges them in the cargo space of a truck. Loading without pallets is also possible. Users can select the required container, pallet, and truck types through the user interface.

The software visualizes the calculation results graphically, making it clear how the available space is used in the container, on the pallet, and in the truck. For a more realistic representation, packing materials such as trays, inserts, and compartments are now displayed directly.

PackAssistant also provides the costs of the calculated variants. The calculation includes, among other things, expenses for different packing materials, containers, and logistics. It specifies the cost per part as well as the derived costs for a container, a pallet, and a complete truckload. For road transport, the program also indicates the cost per trip.

The results show which solution uses space most cost-effectively and how many containers, pallets, or transports are required. They can also be used in quote preparation and logistics costing.

PackAssistant is primarily aimed at industrial companies that frequently pack large quantities of identical parts, including complex-shaped parts. More than 400 customers use the software, which has been installed over 2,000 times worldwide. Fraunhofer SCAI develops the program, while scapos AG, a spin-off from SCAI, handles sales through an international network of distribution partners.