Fraunhofer IML and IGEPA Optimize Mail Order Business

Fraunhofer Institute for Material Flow and Logistics IML and the IGEPA group have established a strategic partnership to optimize processes in mail order. The focus of the collaboration is the AI-supported software CASTN (Carton Set Optimization), which is offered by the IGEPA group as the first third-party provider in Germany and Europe.

The mail order sector is increasingly facing challenges, including oversized cartons, unnecessary filling materials, and rising shipping costs. These factors burden both the environment and the budgets of companies. Additionally, the new EU Packaging Regulation (PPWR), which comes into effect in 2030, mandates a maximum empty space ratio of 50 percent in cartons. The CASTN software provides a solution by assisting companies in finding a suitable standard carton set. The goal is to achieve maximum volume utilization with as few carton sizes as possible, leading to a reduction in overpackaging, material usage, and costs. At the same time, CASTN provides a transparent basis for compliance with regulatory requirements.

Optimization of Packaging Strategy

Bernd Loschelder, Head of the PACKAGING division at the IGEPA group, explains: “With CASTN, we are providing our customers for the first time with an intelligent solution that allows them to specifically align their packaging strategy towards efficiency and sustainability.” He emphasizes that the goal is to provide customers with a solid decision-making basis for selecting packaging and to support them in adapting to new regulatory requirements. The combination of data-driven analyses and years of packaging expertise is intended to accompany companies from strategy to practical implementation.

Fraunhofer IML has developed CASTN over a period of four years to end the use of oversized cartons and actively shape the transition to sustainable shipping processes. Lukas Lehmann, project manager at Fraunhofer IML, highlights: “With the IGEPA group, we gain a strong partner with extensive market knowledge and direct access to companies.” He sees the cooperation as an important step to make CASTN accessible to a broader user group.

The IGEPA group takes a pioneering role by integrating the software into its service portfolio and supporting its customers from the initial analysis discussion to the delivery of tailored packaging. This collaboration represents a paradigm shift: Instead of arbitrarily procuring cartons, the IGEPA group and Fraunhofer IML jointly analyze the actual packaging needs of their customers to create transparency and predictability in the shipping process.

Following the product launch in February 2026, CASTN is expected to establish itself in the market and is already attracting interest in the logistics and retail sectors. The software is well-received by logistics service providers, online retailers, as well as suppliers of conveyor and storage technology and packaging machines. By analyzing the need for carton sizes early on, companies can align their conveyor systems and packaging machines specifically to the optimal standard carton set, leading to cost savings and an improved sustainability balance. Additionally, a solid foundation is created for compliance with future regulatory requirements.

Further information about the software is available at www.castn.de.