pallet.design

Cases per pallet calculator (Ti-Hi)

Summary

Cases per pallet = cases per layer (Ti) × number of layers (Hi). Ti comes from fitting the case footprint on the pallet deck; Hi is the allowed load height above the deck divided by the case height, capped by the weight limit. Enter a case and pallet below.

Case

in
in
in
lb

Pallet and limits

in
in
in
lb
in
lb
in

Layer pattern · Two-block pattern

Top view, pallet length left to right. Blue cases are turned.

Result

Cases per pallet
50
10 × 5 (Ti × Hi)
Load height
55.5 in
1410 mm incl. pallet
Gross weight
1,295 lb
587 kg
Deck coverage
100%
Cube used 92%
Height limits layers (5).

How to calculate cases per pallet

  1. Cases per layer (Ti). Divide the pallet length and width by the case length and width, rounding down, in both orientations. Then try splitting the deck into two blocks with the case turned in one of them. Keep the best count.
  2. Layers (Hi). Subtract the pallet height from the maximum load height and divide by the case height, rounding down.
  3. Weight check. Multiply cases by case weight, add the pallet weight (about 35 to 55 lb for a 48 × 40 wood pallet), and remove layers until the gross is under your limit.

Aim for more than 90% deck coverage with no overhang. If a case size leaves a large gap, a small change to the case dimensions often adds a full row. See pallet stacking patterns, pallet overhang, Ti-Hi and unit load design.

Frequently asked questions

What does Ti-Hi mean?

Ti is the number of cases in one layer (tier) and Hi is the number of layers. A 10 × 5 Ti-Hi is 10 cases per layer, 5 layers high, 50 cases per pallet.

What maximum load height should I use?

Many distribution centers and retailers cap pallet loads at 48 to 60 in including the pallet, and racking positions often allow 48 to 72 in. Your customer’s routing guide or your rack beam spacing sets the real limit.

Should cases overhang the pallet?

No, in most cases. Overhang lets the case walls hang unsupported, which cuts box compression strength sharply, and many retailers reject overhanging loads. Underhang of up to about 1 in per side is common.

Why does the calculator use a two-block pattern?

Turning part of the layer often fits more cases than a single orientation. For a 16 × 12 in case on a 48 × 40 pallet, one orientation fits 9 per layer; a two-block pattern fits 10.

Is column stacking or interlocking better?

Column stacking (every layer identical, corners aligned) keeps the box’s full compression strength. Interlocking (alternate layers rotated) improves stability but can cut stacking strength by up to about half. Stretch wrap usually provides stability, so column stacking is common.