How many boxes to order: reorder points for D2C and plants
Order enough packaging to cover supplier lead time plus a spike buffer — for PackWorks stock packs that is often 2–4 weeks of usage plus festival uplift; for custom print, never buy more than you will sell before the next design change.
Updated 11 Sept 2026 · PackWorks By Velun, Karnal
Simple reorder math
Daily parcels × days until the next delivery lands + safety stock. Safety stock covers courier delays to you, sudden ad-spike volume, and the week your packers discover the wrong size.
| Situation | Cover | Notes |
|---|---|---|
| Stable D2C, stock cartons | 2–3 weeks usage | Reorder when on-hand hits 10–14 days |
| Marketplace + ads volatility | 3–4 weeks | Keep two nearby sizes |
| Monsoon / festive peak | Peak week × 1.5–2 | Book early; print plates queue |
| Custom print run | Sell-through ≤ 60–90 days | Do not overbuy before a rebrand |
Respect pack quantities
You buy packs (10, 25, 50, 100…). Round up to the next pack; do not plan on opening a sealed pack “halfway” across two pin codes if your warehouse is one room. For 3PL lines, standardise five middle sizes so reorder SKUs stay few.
Print and colour special cases
Colour mailers: smaller packs let you test shades without a year’s inventory. Custom flexo: MOQ 500 per size — calculate months of cover at current run-rate before you approve the plate. A beautiful carton you cannot store will get crushed in the aisle.
- One hero size printed; secondary sizes stay plain stock
- Advance payment locks cash — align with cash collection cycle
- Samples first: never land 500 of an untested inner size
Storage reality
Flat cartons hate wet floors. Keep off monsoon concrete on pallets or racks, rotate older packs first, and separate printed lots from plain so packers do not mix. Damaged storage is a hidden reorder driver.