Pallet Configuration Calculator — Cases per Pallet (TI-HI)

Short answerCases/pallet = TI × HI, where TI (cases per layer) = pallet area ÷ case footprint (best of the fits), and HI (layers) = (max load height − pallet height) ÷ case height. Squaring the footprint to the pallet is what cuts wasted deck.

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How it's calculated

Pallet efficiency is two numbers. TI is how many cases tile onto one layer of the pallet deck — set by the case footprint versus the pallet (a GMA pallet is 48 × 40 in = 1,920 in²), counting the better of aligned or pinwheel patterns. HI is how many layers stack under the height limit — trailer or rack opening minus the pallet, divided by case height. Multiply them for cases per pallet; the pattern that wastes the least deck area wins on freight.

TI = ⌊ pallet area ÷ case footprint ⌋ (best pattern) HI = ⌊ (max height − pallet H) ÷ case H ⌋ Cases/pallet = TI × HI

Worked example

Case 12 × 10 × 8 in on a 48 × 40 in pallet.
TI = 1,920 ÷ 120 = 16 cases/layer (tiles exactly).
HI = ⌊(60 − 5.5) ÷ 8⌋ = 6 layers.
Cases/pallet = 16 × 6 = 96 cases.

Reference tables

Cases per layer on a 48×40 GMA pallet (footprint fit)

Case footprint (in)	Cases/layer
12 × 10	16
16 × 12	10
12 × 12	13
24 × 16	5
15 × 10	12

Common stack-height limits

Constraint	Typical clear
Dry van trailer	≈ 100 in
Single rack opening	54–72 in
Floor-stack (double)	≈ 60 in each

A number the tables do not give: a 12×10×8 in case tiles 16 to a layer and stacks 6 high under 60 in — 96 cases on a GMA pallet.

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This calculation is exactly what our packaging / box simulator runs live. Open it to see how the same inputs become a cut plan, stacking strength and pallet fit on your own domain:

Packaging / box simulator▶ OPEN DEMO Storage Rack quote-simulator▶ OPEN DEMO Conduit Fill · NEC▶ LIVE CALCULATOR

FAQ

What do TI and HI mean?

TI is the tie — cases per layer. HI is the high — number of layers. Cases per pallet is TI × HI. The terms come from unit-load and logistics practice.

Aligned or pinwheel pattern?

Whichever wastes the least deck. Pinwheel (interlocked) patterns bind the load better against tipping; aligned columns stack stronger vertically. The best TI often comes from mixing them by layer.

Why does footprint squaring matter?

A case footprint that divides evenly into the pallet leaves little dead deck, so more cases per layer and lower freight per case. A poor fit can waste 10–20% of the pallet.

Does overhang hurt?

Yes — cases hanging past the pallet edge lose most of their compression strength (the corners no longer stack), so a tight fit protects both the box and the load.

This page is a reference aid. Always verify against the pallet footprint (GMA 48×40 or your standard) and load-height limit. Figures shown are for orientation, not a stamped design.

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