Setting Up Your Packaging and Bundling Rules in Gelato Connect
Every production facility has its own way of packaging products — the types of boxes you use, how you bundle multiple products together, and how you prepare shipments for dispatch. Gelato Connect gives you full control to define these packaging and bundling rules so that our system can automatically calculate the best fit for each order, ensuring efficiency, accuracy, and cost optimization.
This guide will help you, as a production facility, to set up your packaging logic inside Gelato Connect from start to finish.
By following this process, you’ll make sure Gelato Connect understands:
What packaging materials you have in your facility (boxes, envelopes, tubes, etc.)
How your products are bundled together in real life
How we should dimensionally calculate and select the right box for every order
How to view and, when needed, override the box selection at the packaging station
Why This Is Important
Setting up your packaging and bundling rules allows Gelato Connect to mirror your actual packing process digitally. Once configured, the system can automatically select the correct box and calculate the most efficient packaging combination based on your rules — saving time, reducing shipping costs, and ensuring your customers receive perfectly packed products every time.
The Setup Process
You’ll go through three main steps to complete your setup:
Upload Your Packaging Inventory
Tell us what boxes and packaging materials you have in your facility. Include details such as box names, internal dimensions, and weights.Set Up Packaging and Bundling Rules
Define how different product types are packed together — for example, how many T-shirts fit in a box, whether posters are shipped separately, or if multiple products can be combined.View and Override Box Selection at the Packaging Station
Once your rules are set, Gelato Connect will automatically choose the right box for each order. At the packaging station, you’ll be able to see which box was selected and, if necessary, override it manually to choose a different box before finalizing the shipment.
Once these steps are complete, Gelato Connect will automatically use your configuration to optimize packaging for every order — helping you reduce wasted space, lower shipping costs, and simplify your fulfillment process.
Step 1: Upload Your Packaging Inventory
The first step in setting up your packaging and bundling rules in Gelato Connect is to define the packaging materials you use at your facility — such as boxes, envelopes, or tubes.
This step tells Gelato Connect what packaging you have available and allows the system to use this data when determining how products are bundled and shipped.
What You’ll Do in This Step
You’ll create digital definitions of your packaging materials by either:
Uploading a pre-filled template file, or
Manually adding packaging materials directly in Gelato Connect.
Each packaging material you define becomes a SKU (Stock Keeping Unit) that Gelato Connect can reference during packaging calculations.
Step-by-Step Instructions
1. Go to the Packaging Material Section
In your Gelato Connect dashboard, search for Packaging Material (or Box Material, depending on your setup).
Here you’ll define all packaging items your facility uses — for example, “Small Corrugated Box,” “Poster Tube 60cm,” or “Mailer Envelope A4.”
2. Download the Packaging Template
Click Download Template to get a pre-formatted file where you’ll fill in details for each box.
You can complete it immediately or return to it later — the system will allow you to skip this step temporarily if needed.
Example of what’s in the template:
Field | Description |
Box Nickname | A simple, human-readable name (e.g., “Small Box”, “A3 Poster Tube”) |
Dimension Unit | Select from the dropdown (usually metric) |
Length, Width, Height | Enter dimensions in your chosen unit |
Weight (grams) | Always enter weight in grams |
Material | Select from dropdown (e.g., Corrugated Cardboard, Plastic, Paperboard) |
Color | Choose from existing predefined colors |
Package Type | Choose from dropdown (e.g., Rectangle Box, Corrugated Box, Tube) |
Customer (optional) | Leave empty if used for all customers, or assign to a specific one |
Tip: Each dropdown (Material, Color, Package Type) uses predefined attributes that already exist in your system. If you don’t see the right option, you can add new ones (see below).
3. Upload Your Completed Template
Once you’ve filled out your template, go back to the Packaging Material section and click Upload File.
Gelato Connect will automatically create SKUs for each defined box, including their dimensions, weights, and other details.
You’ll now see your packaging materials appear in your product list with a product definition and a SKU for each box.
For example, if you uploaded “Box_400x300x200,” it will appear with its dimensions and weight exactly as defined in your file.
Add or Adjust Attributes (Optional)
If a dropdown doesn’t include the value you need — for example, a missing Package Type or Material — you can easily create new attributes.
Go to the Attributes section.
Add a new value (e.g., “Double Wall Corrugated Box”).
Save the attribute — it will automatically appear in the dropdown list for your template next time you download it.
This ensures that all your new values are properly linked to the system and pre-filled in future templates.
Example scenario:
You have three box types at your facility:
Small Corrugated Box (200x150x100mm, 180g)
Medium Corrugated Box (400x300x200mm, 400g)
Poster Tube (60cm length, 250g)
You’d list all three in the template, upload the file, and Gelato Connect would create three unique packaging SKUs that the system can reference when calculating packaging selection.
What Happens Next
After completing this step, your packaging inventory is now visible and ready to use within Gelato Connect.
Each packaging SKU will be used in Step 2: Setting Up Bundling Rules, where you’ll define how specific products fit into these boxes and how multiple items can be combined.
Once your packaging inventory and bundling rules are set up, Gelato Connect will automatically recommend the most suitable box for each order during the packaging process.
This recommendation is based on your defined packaging materials, product dimensions, and bundling logic — ensuring optimized space usage and cost efficiency.
However, there may be times when the recommended box is not available or needs to be changed due to operational reasons (for example, a specific box is out of stock or damaged). In those cases, you can manually override the selected box directly at the packaging station.
Step 2: Set Up Packaging and Bundling Rules
A lot more detail on bundling rules can be found here.
Once you’ve uploaded your packaging materials in Step 1, the next step is to define how your products are bundled together and which boxes or packages they go into.
In this step, you’ll use the Packaging Rules screen in Gelato Connect to tell the system:
Which product models can be packaged together,
Which packaging materials (boxes, tubes, or envelopes) they should use, and
Whether the system should automatically calculate or strictly apply your own packaging logic.
This step forms the foundation of how Gelato Connect automates packaging optimization for your facility.
What Are Packaging Bundling Rules?
Packaging Bundling Rules are configurable conditions that determine:
Which products are bundled together in one package,
How many items can be included per box or bag,
Which shipping methods or dimensional limits apply during packing.
They ensure orders are packed efficiently, safely, and cost-effectively — while still respecting the specific workflows of your facility.
Why They Matter
Setting bundling rules helps Gelato Connect mirror your real-world packaging behavior. Without these rules, the system would package different product models separately, increasing cost and inefficiency.
Bundling rules allow you to:
Reduce damage risk by grouping compatible products correctly,
Optimize dimensional shipping costs,
Support unique handling for certain product types (e.g., apparel, posters, framed prints),
Comply with packaging and branding requirements,
Automate intelligent box selection integrated with Gelato Connect Logistics.
How Bundling Rules Work in the Workflow
Bundling rules are applied automatically during the packaging process as part of the Gelato Connect workflow:
Order Received – The system collects all product, shipping, and destination details.
Group Products – Products are grouped by technical or commercial models.
Fetch Shipment Data – The system checks carrier constraints (weight, dimensions).
Check for Palletization – If pallet shipping is required, that logic is applied first.
Apply Bundling Rules – The system looks for matching rules you’ve configured:
By customer/tenant, product model, or print location,
The highest priority rule is applied first.
Bundle Products – Items that meet rule criteria are bundled and assigned to the defined packaging SKUs from Step 1.
Fallback Handling – Any unbundled products are split by weight or defaulted to calculated boxes.
Step-by-Step: Creating Bundling Rules
1. Open the Packaging Rules Page
In Gelato Connect, search for “Packaging Rules” using the search bar.
This page displays all your existing rules and allows you to create new ones.
Each rule represents a set of instructions that define:
Which product models can be grouped together
Which boxes they go into
Whether to use volume calculation or fixed rules
Which customers or facilities the rule applies to
Tip: Most facilities have 10–30 packaging rules depending on their product variety and packaging complexity.
2. Create a New Rule
Click “Create New Rule.” You’ll see a table with several key fields:
Field | Description |
Rule Name | A descriptive name (e.g., “T-shirt + Mug Bundling Rule”). |
Customer | Select the customer(s) this applies to, or choose “All” for global rules. |
Priority | Determines which rule is applied first. Higher = higher priority. |
Exact Match | Requires the order to match the defined criteria exactly. |
Ignore Volume Calculation | Forces the system to use your rule even if items don’t fit volumetrically (useful for flexible items like apparel or cushions). |
Split Order into Available Packages | Allows the system to divide the order into multiple boxes if one box cannot fit everything. |
Actions | Edit or delete the rule later. |
3. Define Product Combinations
You can add one or more product models to a rule.
For each, specify:
Product Model Name or UID (e.g., “Mug,” “Poster,” “T-shirt”)
Minimum and Maximum Quantity Range (e.g., 1–6 mugs, 1–10 shirts)
Optional Attributes like size or material (e.g., “Canvas 40x60 cm,” “T-shirt XL”)
Each line in your rule table represents an AND condition (must all be true), while multiple selections within the same field represent an OR condition.
Example:
T-shirt (Qty 1–10) AND Bottle (Qty 1–4) = one package
Poster (Qty 1–12) OR Canvas (Qty 1–6) = one package
4. Link to Available Packages
Next, select the packaging materials that this rule should use. These are populated automatically from Step 1 (your uploaded packaging inventory).
For example:
For T-shirts and bottles: select “Medium Corrugated Box (400×300×200mm)”
For framed posters: select “Flat Box (1000×700×50mm)”
If you add multiple boxes, the system will intelligently choose the most efficient one or split the order into multiple boxes if needed.
5. Set Optional Behaviors
You can further refine the rule with the following options:
Ignore Volume Calculation – Always use this box regardless of volume checks (useful for polybags or flexible items).
Split Order into Available Packages – Allows multiple boxes to be used if one isn’t enough.
Calculated Box – If no package is specified, Gelato Connect will automatically calculate a box size by estimating total bundle volume and adding a small buffer (typically 5%).
6. Save and Manage Rules
Once complete, click Save. Your rule will now appear in the Packaging Rules table. You can edit priorities, modify customer assignments, or delete rules at any time.
Example scenarios:
Example 1: Apparel and Bottle Rule
Name: Apparel + Bottle Bundling
Products: T-shirts (1–10), Bottles (1–4)
Packages: 102×88×107 mm box
Settings: Split order into available packages ✔️, Ignore volume ❌, ✅ Optimizes how small apparel and bottles are combined into existing box SKUs.
Example 2: Framed Canvas Rule
Name: Frame + Canvas Bundling
Products: Canvas (1–6), Framed Poster (0–1 optional)
Packages: Predefined frame boxes (3 SKUs)
Settings: Split order ✔️, Ignore volume ❌, ✅ Ensures frames and canvases are packed together using exact-size boxes from your facility.
Example 3: Apparel Bag Rule
Name: Apparel Polybag Rule
Products: T-shirts (1–3)
Packages: Polybag A
Settings: Ignore volume ✔️, ✅ Forces all T-shirts to fit into a single polybag regardless of dimensional fit.
Priority Logic
When multiple rules could apply:
The highest-priority rule is applied first.
If two rules share the same priority, the older rule takes precedence.
Rules can be specific (deterministic) or generic (fallback):
Specific = customer-specific or product-specific rules
Generic = default fallback rules for all other products
What Happens If No Rule Matches?
If no rule matches an order:
Gelato Connect will use default product grouping (by model).
The system will split the shipment by weight or dimension limits if needed.
A calculated box will be generated automatically so no order is left unpacked.
This ensures all shipments are still processed successfully — even without a direct bundling match.
What’s Next
After setting up your packaging and bundling rules, you’re ready to move on to Step 3: View and Override Box Selection at the Packaging Station, where operators can view which box Gelato Connect selects automatically — and manually override it if needed during packing.
Step 3: View and Override Box Selection at the Packaging Station
Purpose of This Step
This step allows your packaging operator to:
See the recommended box and its specifications (material, dimensions, and weight).
Understand that not using the recommended box may affect shipping cost calculations.
Override the automatically selected box with another available packaging option.
Step-by-Step Instructions
1. Review the Recommended Box
When an order arrives at the packaging station, Gelato Connect will automatically display the recommended box based on your packaging and bundling rules.
You’ll see:
The box name and material type.
The dimensions and weight of the box.
A note that explains this is the system-recommended box.
Important: Using a box other than the one recommended can lead to higher shipping costs on your carrier invoice, since dimensional weight and rates may differ.
2. Open the Box Override Menu
If the recommended box is unavailable or not suitable for the order, click on “Change / Override Box.”
A list of all available boxes from your inventory will appear. Each option will show:
Box image (if uploaded)
Material and size details
Shipping method and price difference compared to the recommended option
Tip: Images can be uploaded manually or generated automatically using AI, helping operators easily identify the correct box visually.
3. Compare and Confirm the New Box
Before confirming, review:
The price difference between the recommended and the selected box.
The shipping method associated with the new box.
Any estimated change in cost or weight.
Once reviewed, click “Confirm Override.” The new box selection will now replace the system recommendation for this order.
4. Complete the Packaging Step
After confirming, the new box selection is saved and used for label generation, shipment cost estimation, and invoicing.
You can proceed with printing the shipping label and finalizing the order as usual.
Example scenario:
Let’s say the system recommends “Medium Corrugated Box – 400 × 300 × 200 mm.”
However, you’ve temporarily run out of this size at your facility.
At the packaging station:
You click “Override Box.”
You see “Large Corrugated Box – 450 × 350 × 250 mm” as an available option.
The system shows a small price difference and notifies you of the change in shipping cost.
You confirm the override and proceed to label creation.
What Happens Next
After the override, Gelato Connect will:
Record the new box selection for that order.
Update any shipment calculations accordingly.
Maintain a log of overrides for transparency and future optimization.
This ensures you always have flexibility on the production floor while still maintaining cost visibility and traceability for each shipment.