AI-Estimator now supports packaging estimation for both folding cartons and corrugated boxes. This guide walks you through how to configure packaging templates, die libraries, and folder-gluer machines, then create your first packaging estimate.
(Video) Walkthrough: Estimating Packaging with AI-Estimator
Why Packaging Estimation?
Packaging estimation is typically slow, manual and reliant on experts - resulting in lost jobs and margin opportunities. AI-Estimator solves this by automating flat pattern calculations, die library lookups, imposition layout, and shipping estimates while giving you control to adjust when needed.
How It Works
Describe the Job - Enter dimensions, box style, material, quantity, and print specs. AI maps to template, calculates flat size, checks die library.
Review Imposition - System calculates layout using smallest bounding rectangle. Adjust flat size if boxes can nest more tightly.
Folder-Gluer & Finishing - Speed adjusts based on box complexity, plus any finishing steps.
Die Cost - System detects existing die or applies new die cost. Override if needed.
Delivery - Uses collapsed dimensions for shipping. Override package type if needed.
Creating a Packaging Estimate
Describe the job in the AI chat using natural language, copy/paste from email, or upload a screenshot/PDF.
Example: "5,000 standard tuck-end cartons, 70mm wide by 180mm tall by 70mm deep. 300gsm, with glossy white finish. Full color print on the outside only"
Review the estimate:
Product category, template, and size are auto-populated
Die cost type (existing or new die) is auto-detected
Substrate and print specs are matched
Adjust imposition if needed by changing flat size width/height to get more boxes per sheet.
Toggle die type between existing and new die if the detection doesn't match your inventory.
Review delivery and override shipping package or collapsed dimensions if needed.
Configuration Setup
Complete these six steps before creating packaging estimates:
1. Define Packaging Category
In Product Setup Sheet > Categories tab, add "Packaging" with Imposition Type set to "packaging".
2. Configure Production Steps
In Product Setup Sheet > Products tab, define your workflow (e.g., Print → Die-cut → Crease → Folder-glue).
3. Add Folder-Gluer Machine
In Machine & Substrate Setup Sheet > Bind;folder-gluer tab, configure machine speed, rates, and speed adjustment formula based on glue points.
4. Add Packaging Templates
In Product Setup Sheet > PackagingTemplates tab, use pre-configured FEFCO/ECMA templates or create custom ones. Each template defines how to convert 3D dimensions to flat sheet size.
5. Add Die Library
In Product Setup Sheet > DieLibrary tab, list your physical dies with reference number, template code, and dimensions. System uses this to detect existing dies.
6. Enable Packaging in Standard Tabs
Update Sizes, PageColor, PackagingConfiguration, and ShippingConfiguration tabs to include packaging options.
Configuration Templates
Gelato maintains up-to-date configuration sheet templates. Use these templates as a reference to copy/paste or see example to setup your own configuration.