Rigid Packaging vs Flexible Pouch Savings Calculator
Compare weight, shipping volume, freight and purchase cost of your current rigid pack with a flexible pouch, and see the estimated annual saving.
Default numbers are examples only, typical value, please confirm with your data.
Rigid packaging
Cans, bottles, jars or tubs
Use the same currency for both packs.
Flexible pouch
Stand-up or flat pouch
Use the same currency for both packs.
Shipping assumptions
Typical value, please confirm with your data.
Allows for pallet gaps and loading losses.
CO2e comparison (optional)
Enter your own verified CO2e data per 1,000 pieces. No default factors are provided.
Results
Total annual saving
—
Weight reduction
—
Pouch weight versus rigid pack
Material saved per year
—
Packaging weight not purchased
Extra pieces per container
—
Pouch pieces minus rigid pieces
Containers saved per year
—
Fewer containers for the same volume
CO2e saved per year
—
Cost per 1,000 pieces
Detailed comparison
| Item | Rigid packaging | Flexible pouch |
|---|---|---|
| Weight per piece | — | — |
| Price per piece | — | — |
| Shipping volume per piece | — | — |
| Freight per piece | — | — |
| Pieces per container | — | — |
| Containers per year | — | — |
| Annual purchase cost | — | — |
| Annual freight cost | — | — |
| Annual total cost | — | — |
| Carton gross weight | — | — |
Covers packaging purchase and freight only. Filling and labour costs are not included.
Formulas and assumptions
- Weight per piece comes from your input; imperial values are converted internally to grams, kilograms, centimetres and CBM.
- Weight reduction = (1 - pouch weight / rigid weight) x 100%.
- Material saved per year (tonnes) = (rigid weight - pouch weight) in grams x annual volume / 1,000,000.
- Shipping volume per piece = carton CBM / pieces per carton. CBM from dimensions = L x W x H in cm / 1,000,000.
- Freight per piece = shipping volume per piece x freight rate per CBM.
- Pieces per container = container CBM x fill rate / shipping volume per piece. Containers per year = annual volume / pieces per container.
- Total annual saving = (rigid price - pouch price) x annual volume + (rigid freight - pouch freight) x annual volume.
- CO2e saved (tonnes) = (rigid - pouch CO2e per 1,000 pcs) x annual volume / 1,000,000, using only your own data.
- The chart compares purchase cost, freight cost and total cost per 1,000 pieces.
- Default numbers are examples only. Replace them with your own data.
- Typical value, please confirm with your data.
- Filling line changes may be required. We can advise.
How to use
Enter your rigid pack
Fill in empty weight, price, pieces per carton and carton CBM for your current can, bottle or tub.
Enter the flexible pouch
Add the same data for the pouch. Default numbers are examples only, typical value, please confirm with your data.
Read the results
Results update as you type. Switch between Metric and Imperial at any time.
A worked example
Using the default example values (annual volume 1,000,000 pieces, freight 60 per CBM, container 68 CBM at 85% fill):
- Weight reduction: 1 - 12 / 120 = 90%.
- Material saved: (120 - 12) x 1,000,000 / 1e6 = 108 tonnes per year.
- Shipping volume per piece: rigid 0.045 / 24 = 0.001875 CBM; pouch 0.040 / 100 = 0.0004 CBM.
- Freight per piece: rigid 0.1125; pouch 0.024.
- Pieces per container (57.8 CBM usable): rigid 30,827; pouch 144,500.
- Containers per year: rigid 32.4; pouch 6.9; about 25.5 fewer.
- Purchase price difference: (0.45 - 0.18) x 1,000,000 = 270,000. Freight difference: (0.1125 - 0.024) x 1,000,000 = 88,500.
- Total annual saving: 358,500 (example numbers, typical value, please confirm with your data).
FAQ
Are the default prices real quotes?
No. They are example numbers only. Replace them with your own figures.
Does the calculator include filling or labour costs?
No. It covers packaging purchase price and freight only.
How is carton volume calculated?
Enter CBM directly, or enter length, width and height in cm and the tool computes CBM.
Can I use my own CO2e factors?
Yes. Enter your own verified data. We do not provide default factors.
Will my filling line work with pouches?
Filling line changes may be required. Contact us and we can advise.
Related tools
Have a project in mind?
Share your product and volume and we will prepare a quotation.
Filling line changes may be required — we can advise.
Results are estimates for planning purposes. Final specifications and prices are confirmed in your quotation.