Pallet Loading & Stacking Calculator (TI × HI)
Determine cartons per pallet, TI × HI stacking configurations, loaded height, gross weight, and visual layouts.
Live Calculation Results
Cartons per pallet
TI 10 × HI 6 · best layout found
- TI (cartons per layer)
- 10
- HI (layers)
- 6
- Pallets required
- 9
- Cartons on final pallet
- 20
- Loaded height
- 1,650 mm
- Remaining height
- 150 mm
- Cargo weight (full pallet)
- 720.00 kg
- Pallet tare
- 25.00 kg
- Gross pallet weight
- 745.00 kg
- Remaining payload
- 280.00 kg
- Footprint utilization
- 100.0%
- Volume utilization
- 100.0%
What this means
- Best layout found: 10 cartons per layer × 6 layers = 60 cartons per pallet.
- Height is the limiting constraint: another layer would exceed the maximum loaded height.
- The order of 500 cartons needs 9 pallets; the last one carries 20.
Colours show different carton orientations. Drawn from the calculated coordinates.
6 layers. Identical items behind each other are drawn once.
| Layer | Cartons | Orientation |
|---|---|---|
| 1 | 10 | L along X, W along Y, H vertical |
| 2 | 10 | L along X, W along Y, H vertical |
| 3 | 10 | L along X, W along Y, H vertical |
| 4 | 10 | L along X, W along Y, H vertical |
| 5 | 10 | L along X, W along Y, H vertical |
| 6 | 10 | L along X, W along Y, H vertical |
Assumptions used
- Rectangular, identical cartons; every layer is packed flat on the one below.
- Objective: satisfy all limits, then maximise cartons per pallet, then footprint use. Search covers guillotine-cut arrangements of the allowed orientations, so this is the best tested arrangement, not a proof of the global optimum.
- Dimensions are rounded to the nearest millimetre for packing.
- Geometric spatial layout estimate only. Does not evaluate corrugated carton compression strength (ECT/BCT), pallet overhang safety, or transit dynamic stability. Physical testing or engineering review is required for shipping safety verification.
- Actual loading may require clearance, securing, stacking, and handling allowances.
How many of these pallets fit in a container? →Load loose cartons into a container →
Planning Notice & Scope Boundary
Geometric spatial layout estimate only. Does not constitute an engineering determination of carton compression strength, pallet overhang safety, or transit stability. Verify box compression ratings (ECT) and securing methods prior to transport.
Formula & Calculation Methodology
TI = Cartons per layer (tested across aligned, rotated, and mixed strip patterns). HI = Layers high. Total Cartons = TI × HI.
Cartons per Pallet = TI * HI| Variable | Definition & Basis |
|---|---|
| TI | Tier count: cartons arranged on the pallet deck footprint |
| HI | High count: number of vertical layers within height limits |
| Gross Weight | Cargo Weight + Pallet Tare Weight |
Worked Example: Standard GMA Pallet Stacking
Loading 400 × 300 × 250 mm cartons weighing 12 kg each onto a standard 1200 × 1000 mm pallet (tare 25 kg, max height 1800 mm).
Input Parameters
- Carton Dims400 × 300 × 250 mm, 12 kg
- Pallet Dims1200 × 1000 mm, deck 150 mm
- Max Height1800 mm
Step-by-Step Calculation Breakdown
- 1Pallet footprint 1200 × 1000 mm accommodates 10 cartons per layer (3 rows of 400mm along length = 1200mm; widths 300+300+300 = 900mm fits 1000mm).
- 2Available height: 1800 mm - 150 mm deck = 1650 mm for cartons.
- 3Layers (HI): floor(1650 ÷ 250) = 6 layers high.
- 4Cartons per pallet: 10 per layer × 6 layers = 60 cartons per pallet.
- 5Gross pallet weight: (60 × 12 kg) + 25 kg tare = 745 kg.
Assumptions Used
- Evaluates rectangular floor packings (aligned and rotated strip orientations).
- Loaded height includes the thickness of the pallet deck.
- Weight capacity checks cargo payload against entered pallet maximums.
Important Limitations
- Represents best feasible rectangular arrangements evaluated, not a proven global mathematical maximum for non-orthogonal arrangements.
- Does not model box bulging, strapping tension, or shrink-wrap compression.
Authoritative Standards & Sources
ISO 6780 lists six principal footprints: 1200×800, 1200×1000, 1219×1016, 1067×1067, 1100×1100 and 1140×1140 mm (plus 1165×1165 in later editions).
EPAL Euro pallet 1200 × 800 mm ↗
The Euro pallet footprint is 1200 × 800 mm.
Frequently Asked Questions
What does TI and HI mean in warehousing?
TI (Tier) is the number of cartons that fit on a single pallet layer. HI (High) is the number of layers stacked vertically. TI × HI equals the total cartons per pallet.
What is a standard pallet size in the US vs Europe?
In the US and Canada, the standard GMA pallet is 48 × 40 inches (1219 × 1016 mm). In Europe, the standard EUR/EPAL pallet is 1200 × 800 mm.
Should boxes overhang the pallet edge?
Generally, no. Overhang removes direct deck support from underneath the carton corners—where ~60–70% of corrugated compressive strength is concentrated—and exposes packaging to puncture damage during forklift handling and racking.
What to Calculate Next
Freight planning connects sequentially from package dimensions to freight class, pallets, and full equipment: