Pallet calculator

Understanding pallet patterns (TI × HI)

Warehouse and logistics operations measure pallet configurations using TI × HI:

• TI (Tie): The number of cartons or cases per full layer on the pallet.
• HI (High): The number of layers stacked vertically on the pallet.
• Total load: TI × HI = Total cases when every layer is full.

This calculator determines the most efficient uniform carton orientation on your pallet base without allowing carton overhang, then verifies that the load respects both your maximum trailer height and racking weight limits.

A worked example

Suppose you pack jars into cases measuring 16 inches long, 12 inches wide, and 10 inches high, each weighing 25 lbs. You load onto a sample 48×40 inch wooden pallet (6 inches tall, 40 lbs tare) with a 60-inch trailer door height limit:

• Layer orientation: Laying cases with length along pallet length fits 3 × 3 = 9 cases per layer (48/16 = 3, 40/12 = 3). The reverse orientation fits (48/12 = 4) × (40/16 = 2) = 8 cases. The calculator selects 9 cases per layer.
• Available stacking height: 60 in maximum height minus 6 in pallet height = 54 in clearance. 54 in / 10 in case height = 5 full layers (50 in case stack).
• Total dimensions: 5 layers × 9 cases = 45 cases. Loaded height is 56 in (6 in + 50 in). Gross weight is 40 lb + (45 × 25 lb) = 1,165 lb, comfortably under the 2,500 lb limit.

Common mistakes

This layout excludes overhang. Enter the measured empty pallet height and weight when checking loaded dimensions and weight. A weight limit may leave the top layer partly filled; do not multiply the full-layer count by every layer in that case. This calculator does not assess load stability.