Fraunhofer SCAI integrates truck loading and cost analysis into PackAssistant

Bridging the gap between packaging design and logistics execution

For decades, the industrial packaging sector has operated with a structural disconnect: packaging engineers designed containers to protect complex parts, while logistics managers scrambled to fit those containers efficiently into trucks. In August 2026, the Fraunhofer Institute for Algorithms and Scientific Computing (SCAI) effectively closed this gap by expanding its PackAssistant software to include comprehensive pallet and truck load planning, alongside granular cost calculations.

This update marks a significant shift in how industrial packaging is conceptualized. By incorporating the later stages of the transport chain directly into the initial 3D packaging planning phase, Fraunhofer SCAI is transforming a purely structural design tool into a strategic commercial asset. Users can now evaluate multiple packaging solutions not just on their protective qualities, but on their direct impact on freight spend.

Beyond the bounding box: The value of actual geometry

The core strength of PackAssistant has historically been its ability to arrange identical, complex-shaped parts within a container using 3D CAD data. Unlike rudimentary software that relies on simple length, width, and height measurements—often resulting in inefficient "bounding box" calculations—PackAssistant analyzes the actual geometry of the component. This allows for nesting and interlocking arrangements that maximize spatial density while preventing part-to-part damage.

With the 2026 update, this high-fidelity spatial analysis extends outward. The software now visualizes packing materials such as trays, inserts, and compartments directly within the interface, providing a highly realistic representation of the final load. From there, it calculates the optimal stacking of these containers onto pallets, and subsequently, the arrangement of those pallets within a standard truck trailer.

Granular cost calculation for competitive quoting

Perhaps the most critical addition for contract packagers and corrugated converters is the new financial modeling capability. PackAssistant now calculates the exact costs associated with different packaging variants. The system factors in the expenses for specific packing materials, the containers themselves, and the logistics overhead.

The output provides a highly detailed breakdown: cost per individual part, derived costs for a fully loaded container, pallet costs, and the total expense for a complete truckload. For road transport operations, the software explicitly indicates the cost per trip. This level of transparency is invaluable during the quote preparation process. Packaging suppliers can now present their clients with data-backed proposals that prove how a slightly more expensive, custom-engineered internal partition might reduce the total number of required truck trips, ultimately lowering the total cost of ownership.

Market footprint and industry adoption

The software, developed by Fraunhofer SCAI and distributed globally through scapos AG and its network of partners, has already established a strong foothold in the automotive, mechanical engineering, and supplier industries. With over 400 active customers and more than 2,000 installations worldwide, PackAssistant is a recognized standard for handling large quantities of identical, complex parts.

As freight rates remain a volatile component of the global supply chain in 2026, the ability to eliminate "shipped air" is no longer just an environmental sustainability target; it is a fundamental margin-protection strategy. By linking the micro-level geometry of a manufactured part to the macro-level economics of a truckload, Fraunhofer SCAI is providing the exact type of data integration the industry currently demands.

The integration of logistics cost calculations directly into the CAD-based packaging design phase is a highly pragmatic evolution that will save industrial packagers countless hours of manual spreadsheet analysis. Will the next frontier for packaging software be real-time dynamic pricing integration with global freight carriers to optimize material choices on the fly? Follow The Paper for daily news, market signals and key updates from the global paper, corrugated and packaging industry. — Sigue toda la actualidad del sector en www.thepaper.ai