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Order Packing Optimisation (3D Visualisation) 

Purpose 

The Order Packing Optimisation feature allows Cario to automatically pack unpacked products from a warehouse order into suitable containers, converting them into transport units for consignments. 

Using a 3D Visualisation Packing Optimiser, this feature: 

  • Reduces manual packing decisions 
  • Improves space utilisation 
  • Minimises packing errors 
  • Provides visual confidence before consigning to carriers 

This is especially valuable for high-volume, mixed-item, or palletised freight. 

 

What Is Order Packing Optimisation? 

Order Packing Optimisation: 

  • Automatically packs Products (unpacked goods) into Containers 
  • Converts those containers into Shipment / Transport Units 
  • Allows users to visually review the packing solution in 3D 
  • Preloads the optimised result directly into Create New Consignment 

 

Where to Access This Feature 

 Warehouse → Orders → Order Maintenance 

⚠️ This feature must be enabled on your tenant. 
If it is not visible, request activation from Cario Support. 

 

Prerequisites & Configuration

1. Tenant & Customer Configuration

The following settings must be enabled: 

Customer Configuration → General Tab 

  • ✅ Enable Order Pack 
  • ✅ Product Dimension Tolerance (cm) (optional) 

⚠️ Order Pack cannot be enabled at a customer level if it is disabled at a tenant level. 

 

2. Product Dimension Tolerance (cm)

This setting adds a buffer to product dimensions during packing. 

Example: 

  • Product size: 30 × 30 × 30 cm 
  • Tolerance: 1 cm 
  • Treated as: 31 × 31 × 31 cm 

Important Consideration: 

  • Helps avoid tight or unrealistic packing 
  • Can significantly change packing outcomes 
  • Should be used conservatively 

⚠️ Example: 
A 60 × 60 × 60 cm container fits four 30 cm cubes 
With 1 cm tolerance → only one cube may fit 

 

Product Configuration (Critical Step)

3. Configure Products Correctly

Navigate to: 
Maintenance → Products 

Click the ➕ (Add Product) button. 

4. Required Product Settings forOptimisation

The following fields directly impact the optimiser: 

Shipping Container 

  • ✅ Tick this if the product is a container 
  • At least one shipping container must exist per customer 

Weight, Length, Width, Height 

  • Products: actual item weight and dimensions 
  • Containers: 
  • Weight = maximum allowable load 
  • Dimensions = internal usable space only 

 

5. Advanced Packing Settings

Qty per Pallet 

  • Defines how many items form a complete pallet 
  • Optimiser prioritises full pallets 
  • Ignored if impossible to pack 

Qty per Layer 

  • Defines items per layer on a pallet 
  • May be overridden by load position rules 

Can Rotate 

  • Allows product rotation for better fit 
  • ❌ Disable for orientation-sensitive goods 

Type / Palletised 

  • If Pallet, Skid, or Palletised is enabled: 
  • Adds 15 cm height 
  • Adds 38 kg weight 
  • Reduces usable container space 

Preferred Load Position 

  • Top – stays near top 
  • Bottom – stays near bottom 
  • Neutral – system optimises placement 

 

Creating an Order for Optimisation

6. Create an Unpacked Order

Navigate to: 
Warehouse → Create Order 

You will see two sections: 

Product Dimensions & Weight 

  • For unpacked products 
  • These will be automatically packed 

Shipment Dimensions & Weight 

  • For already packed transport units 

 

7. Add Products

  1. Enter the Product Code 
  2. Add required quantities 
  3. Click Create 
  4. Click OK 

 

Using Order Packing Optimisation

8. Open Order Maintenance

Warehouse → Orders → Order Maintenance 

Locate your unconsigned order. 

 

9. Pack & Create Consignment Icon

If enabled, you will see a new icon: 

  • 🚚 Create Consignment 
  • ✏️ Update Order 
  • 🗑️ Delete Order 

➡️ 📦 Pack & Create Consignment 

 

3D Visualisation Packing Screen

10. Review Packing Solution

You can view: 

  • Container usage 
  • Packing order (bottom-left panel) 
  • Pallet/skid representation (brown base) 
11. Navigation Controls
  • Right-click + drag: Rotate 
  • Left-click + drag: Pan 
  • Mouse wheel: Zoom in/out 

 

12. Printing & Exporting

  • Click Print to capture current view 
  • Printing is based on current camera angle 
  • Use Print/Export to generate a PDF with: 
    • Visual snapshot 
    • Product & container summary 

 

13. OptimisationTools 
  • Redistribute by Volume 
    Attempts to balance items evenly across containers 

 

Creating the Consignment

14. Create Consignment

  1. Click Create Consignment 
  2. System preloads: 
    1. Transport units 
    2. Dimensions & weights 
  3. Optional: 
    1. Reopen optimised view 
    2. Show item labels 

Click CREATE to finalise. 

 

 

Final Outcome

15. Confirm Consigned Status

  1. Return to Orders Maintenance 
  2. Tick Consigned

  3. Your packed order will now appear as Consigned 

 

Summary 

The 3D Order Packing Optimisation feature: 

  • Automates complex packing logic 
  • Improves accuracy and efficiency 
  • Provides visual confidence before freight booking 
  • Seamlessly transitions orders into consignments 

It is designed to ensure optimal space utilisation, reduced freight costs, and fewer packing errors across warehouse operations.