By Paul R Salmon FCILT, FSCM
In the age of e-commerce acceleration, sustainability targets, and razor-thin logistics margins, the question is no longer if supply chains should automate measurement — it’s why haven’t they already?
Volumetric scanners, once seen as specialist equipment for high-volume courier hubs, are now becoming standard across the logistics landscape. By replacing manual tape measures, clipboards, and guesswork with automated precision, organisations are unlocking faster throughput, higher billing accuracy, and valuable data for optimisation.
This article explores the technology, benefits, and strategic implications of adopting volumetric scanners — and why “measure no more” is set to become a defining operational principle in the next decade.
1. What Are Volumetric Scanners?
At their core, volumetric scanners are systems that automatically calculate an object’s dimensions (length, width, height) and volume, often in real time as it passes through a measurement zone. Most also integrate with weighing scales to determine dimensional weight (DIM), the metric used by carriers to charge for freight space rather than just physical mass.
How they work:
3D Imaging: Using laser, infrared, LiDAR, or stereoscopic cameras, the system maps the item’s shape. Data Processing: Algorithms calculate cubic volume and store the data. Integration: Results feed directly into Warehouse Management Systems (WMS), Transport Management Systems (TMS), or billing platforms.
They can be fixed (e.g., on conveyor belts), mobile (e.g., mounted on forklifts), or handheld (e.g., portable scanning devices for field operations).
2. The Case for “Measure No More”
Traditional manual measurement in logistics is slow, inconsistent, and prone to error. A single operator with a tape measure can take 30–90 seconds to log an item’s dimensions — not including the risk of rounding errors or misreading.
With volumetric scanners:
Speed: Measurements take under a second. Accuracy: Tolerances can be as tight as ±2 mm. Traceability: Every scan is digitally recorded, removing disputes over shipment size.
This automation is not just about saving time — it’s about enabling an accurate, defensible, and data-rich operational environment.
3. Benefits Across the Supply Chain
3.1 Cost and Revenue Protection
Accurate Billing: Prevents revenue leakage by ensuring customers are charged for true space usage. Carrier Compliance: Avoids penalties for incorrect DIM declarations. Optimised Transport: More accurate load planning reduces the number of vehicles or trips required.
3.2 Operational Efficiency
Eliminates manual measurement bottlenecks at goods-in and dispatch. Integrates with pick-and-pack processes for right-sized packaging production. Frees staff for higher-value tasks.
3.3 Sustainability Impact
Reduces empty space in packaging, cutting void fill materials. Improves cube utilisation in transport, lowering fuel burn and emissions per item shipped. Generates data for carbon reporting and sustainability compliance.
3.4 Data-Driven Decision Making
Provides digital twins of inventory for modelling warehouse space use. Informs procurement of packaging materials based on actual product dimensions. Enables SKU-level volumetric data for e-commerce and product listings.
4. Key Use Cases
4.1 Courier & Parcel Hubs
High-volume sorting centres depend on fast, accurate measurements to assign parcels to the right routes, calculate DIM charges, and feed sortation algorithms. Volumetric scanners here are integrated directly into conveyor systems, capturing data on thousands of parcels per hour.
4.2 E-Commerce Fulfilment Centres
Right-sizing packaging at scale is only possible if product dimensions are known. Scanners feed data into automated box-making machines, producing custom-fit cartons that reduce waste and shipping costs.
4.3 Manufacturing & Assembly
Production lines can scan items as they leave final assembly, updating ERP systems with precise dimensions for outbound logistics planning.
4.4 Air & Sea Freight
Accurate volumetric data is essential for container loading plans and air freight manifests, ensuring compliance with space and weight limits.
5. Technology Landscape
Volumetric scanning technology is advancing rapidly. Key categories include:
Static Cubing Stations: Fixed installations at goods-in/goods-out points for pallet or parcel scanning. In-Motion Conveyor Systems: Capture volumetrics without stopping the flow of goods. Forklift-Mounted Scanners: Measure pallets directly in racking or during movement. Handheld Devices: Portable units for field operations or low-volume environments.
Emerging innovations:
AI-assisted object recognition for irregular shapes. Cloud integration for centralised dimension databases. Augmented reality (AR) interfaces for visualising space use.
6. Implementation Considerations
Adopting volumetric scanning is not just about installing hardware — it’s a process change.
6.1 Integration
Ensure the scanner’s output is compatible with your WMS/TMS. Configure data to update SKU master files automatically.
6.2 Training
While scanning is automated, staff need training on exceptions (e.g., items outside the scanner’s range or reflective surfaces).
6.3 ROI Analysis
Savings come from labour efficiency, reduced disputes, packaging optimisation, and improved transport fill rates. Payback periods can be under 12 months in high-volume environments.
6.4 Data Governance
Treat volumetric data as a critical data element. Maintain accuracy by recalibrating scanners regularly.
7. Strategic Impact on Supply Chains
Volumetric scanners are more than an operational upgrade — they are enablers of supply chain transformation.
7.1 Revenue Assurance
Shippers lose millions annually due to under-measurement. Automated scanning closes this gap permanently.
7.2 Collaboration with Partners
When volumetric data is shared across the chain, it streamlines cross-docking, consolidations, and freight pooling.
7.3 Sustainability Metrics
Governments and customers increasingly demand carbon reporting. Volumetric data directly supports accurate emissions calculations per shipment.
7.4 Competitive Advantage
Speed of processing and accuracy of billing can be market differentiators, especially in e-commerce fulfilment and last-mile delivery.
8. The “Measure No More” Future
The phrase “measure no more” reflects a shift from manual, subjective, and reactive measurement to automated, objective, and proactive space management. Over the next five years, we can expect:
Ubiquity: Volumetric scanning to be as common as barcode scanning today. Autonomy: Integration into autonomous mobile robots (AMRs) for self-measuring inventory moves. Predictive Packaging: AI using historical volumetric data to pre-allocate packaging before orders are even picked. Sustainability Mandates: Regulatory push for volumetric data to optimise transport utilisation and reduce emissions.
9. Lessons from Early Adopters
Early adopters report measurable gains:
Courier Network (UK): Reduced rework from carrier remeasure charges by 85%, saving £2.4m annually. E-Commerce Retailer: Cut packaging costs by 19% through automated box-sizing. 3PL Warehouse: Increased goods-in throughput by 30% without additional staff.
10. Final Thoughts
Volumetric scanners are no longer niche technology — they’re becoming a foundational tool for modern, data-led supply chains. The shift to “measure no more” is about speed, accuracy, and sustainability, but also about building the digital infrastructure for a more connected and efficient logistics ecosystem.
Those who adopt early stand to gain not just operational improvements but strategic advantages in cost control, customer trust, and environmental performance. In a world where every cubic centimetre and every gram of CO₂ matters, the question isn’t whether you can afford to invest in volumetric scanning — it’s whether you can afford not to.
Author: Paul Salmon FCILT
Defence Supply Chain & Logistics Leader
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