Pallet TI HI Calculator: How to Use It

A pallet TI-HI calculator works out how many cases fit on a pallet (TI = “Tier In,� cases per layer) and how many layers high you can stack (HI = “High�) before exceeding the pallet’s weight limit. You enter the pallet dimensions, case dimensions, case weight, and the maximum pallet weight, and the calculator returns the total number of cases per pallet and the number of layers. This is the same math freight coordinators and warehouse staff use to plan shipments, quote freight, and avoid overloading pallets.

Formula

The calculator uses two independent calculations. First, the cases per layer (TI) is the number of cases that fit along the pallet length multiplied by the number that fit along the pallet width, using integer division (you can’t place a partial case):

TI = floor(Pallet length / Case length) × floor(Pallet width / Case width)

Second, the maximum layers (HI) is the largest whole number of layers that keeps the total weight under the pallet’s weight limit:

HI = floor(Max pallet weight / (Case weight × TI))

Total cases per pallet = TI × HI. All dimensions are in inches, weights in pounds. If you use metric, convert centimeters to inches (1 cm = 0.3937 in) and kilograms to pounds (1 kg = 2.2046 lb) before entering, or use a metric unit converter first.

Worked Example

Using the default values: pallet 48 in × 40 in, case 12 in × 10 in, case weight 15 lb, max pallet weight 2000 lb.

1. Cases along length: floor(48 / 12) = 4
2. Cases along width: floor(40 / 10) = 4
3. TI = 4 × 4 = 16 cases per layer
4. Weight per layer: 16 × 15 = 240 lb
5. HI = floor(2000 / 240) = 8 layers
6. Total cases = 16 × 8 = 128 cases

That matches the calculator’s output: 128 total cases, 8 layers, 16 per layer.

Why TI and HI Matter in Freight

TI-HI is a standard planning figure in logistics. It tells you how many cartons fit on a pallet before you build it, which drives three decisions:

• Freight class and cost: Carriers use pallet count and weight to rate LTL (less-than-truckload) shipments. A higher TI-HI means fewer pallets for the same number of cases, which often lowers total freight cost.
• Warehouse storage: Rack capacity is rated in weight per level. Knowing the loaded pallet weight prevents overloading racks.
• Loading trailers: A standard 53-ft dry van fits about 26 standard 48×40 pallets on the floor. If your pallet is taller, you may only get two high instead of three, affecting how many pallets fit per truck.

The TI-HI number also appears on bill of lading documents and is used by vendors to confirm they can ship a full order on a single pallet.

How to Choose Pallet and Case Dimensions

Pallet sizes vary by region and industry. The most common in North America is the 48×40 in GMA pallet. Other standard sizes include 42×42, 48×48, and 40×48. In Europe, the EUR pallet is 1200×800 mm (about 47.2×31.5 in). Your case dimensions are fixed by your product, but you can choose a pallet that maximizes TI.

To maximize cases per layer, rotate the case orientation. The calculator assumes cases are placed with their length along the pallet length and width along pallet width. In practice, you can turn cases 90 degrees if that yields more per layer. For example, a 12×10 case on a 48×40 pallet gives 4×4 = 16. If you rotate the case so 10 in is along the 48-in side and 12 in along the 40-in side, you get floor(48/10)=4 and floor(40/12)=3, so 12 per layer – worse. Always test both orientations.

Common Mistakes and How to Avoid Them

• Mixing units: Entering pallet length in feet and case length in inches will give a wrong TI. Keep all dimensions in the same unit.
• Ignoring overhang: Cases that hang over the pallet edge can be damaged or cause instability. Most shippers allow no more than 1 inch overhang per side. If your cases overhang, reduce the effective pallet length/width by the overhang amount.
• Forgetting the pallet’s own weight: The max pallet weight is the total allowed weight, including the pallet. If the pallet weighs 50 lb, subtract that from the max before calculating. For a 2000-lb max, use 1950 lb as the load limit.
• Rounding down incorrectly: You can’t have a partial case or a partial layer. Always round down to the nearest whole number. The calculator does this automatically.
• Not accounting for stretch wrap and dividers: These add weight. If you use heavy wrap or slip sheets, add that weight to the case weight or subtract from the max.

Limits of the TI-HI Calculation

The TI-HI formula assumes a perfect rectangular grid and that every case is identical. Real pallets often have gaps, edge protectors, or irregular shapes. The weight limit is a structural constraint, but stability matters too: a pallet that is 10 layers high might topple even if it’s under the weight limit. Most freight carriers impose height limits (often 48–72 inches total) that are not part of the pure TI-HI math. Always check with your carrier for specific height and weight restrictions.

Also, the pallet’s maximum weight rating is set by the pallet manufacturer and may be lower than what a forklift can lift. For safety, never exceed the pallet’s rated capacity, and confirm with your warehouse supervisor if you are unsure.

Frequently Asked Questions

What does TI and HI stand for?

TI stands for “Tier In,� meaning the number of cases in one layer on the pallet. HI stands for “High,� meaning the number of layers stacked on the pallet. Together they describe the pallet load pattern.

How do I calculate TI and HI by hand?

Divide the pallet length by the case length and round down. Do the same for width. Multiply those two numbers to get TI. Then divide the maximum pallet weight by (case weight × TI) and round down to get HI. Multiply TI by HI for total cases.

Can I use the same calculator for different pallet sizes?

Yes, the calculator accepts any pallet length, width, and weight limit. Just enter the dimensions in inches and the weight in pounds. For metric, convert to inches and pounds first.

What if my cases are not rectangular?

This calculator assumes rectangular boxes. For cylindrical or irregular shapes, the packing density is lower. You may need to test actual placement or use a specialized packing calculator.

Why does the calculator sometimes give fewer layers than expected?

Because it uses the weight limit. If your cases are heavy, the weight limit is reached before the height limit. The calculator always respects the weight constraint, which is the safer approach.

Does the calculator account for pallet height or truck height?

No, it only considers weight and footprint. For truck or rack height, you need to know the maximum allowed pallet height and divide by the case height to get a height-based layer count, then take the smaller of the two layer counts.

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in pl | Pallet length | in | 48 | 0 | 120
in pw | Pallet width | in | 40 | 0 | 120
in cl | Case length | in | 12 | 0 | 60
in cw | Case width | in | 10 | 0 | 60
in cwt | Case weight | lb | 15 | 0 | 200
in maxw | Max pallet weight | lb | 2000 | 0 | 50000
out total | Total cases per pallet | cases | floor(floor(pl / cl) * floor(pw / cw)) * floor(maxw / (cwt * floor(pl / cl) * floor(pw / cw))) | 0
out layers | Layers high | layers | floor(maxw / (cwt * floor(pl / cl) * floor(pw / cw))) | 0
out perlayer | Cases per layer | cases | floor(pl / cl) * floor(pw / cw) | 0