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Pallet Stacking Optimizer

Find out how many boxes fit on a pallet in seconds. Enter your case and pallet, and get the TI×HI (cases per layer × layers), total cases per pallet, footprint use, load weight, and how many pallets your order needs.

Your case / box
Pallet & limits

Recent pallets

  • Your recent pallet configurations appear here on this device.

3D pallet preview

Stacked loadPallet

Drag to rotate · grid = cases per layer, lines = layers

Total cases per pallet—
TI — × HI —
Enter your case and pallet to see the best stack.
  • Cases per layer (TI) —
  • Layers high (HI) —
  • Footprint used —
  • Total load weight —
  • Total height (with pallet) —

Column-stack estimate (cases aligned). Interlocking can sometimes fit more but reduces stacking strength. Confirm load limits and retailer TI×HI rules before shipping.

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How many boxes fit on a pallet?

The answer comes down to two numbers: TI (cases per layer) and HI (layers high). Multiply them and you get the total cases per pallet. This pallet calculator tests both case orientations to find the best cases per pallet, then caps the layers by your height and weight limits — so you get an accurate TI×HI, footprint utilization, total load weight, and the number of pallets your order needs. It works for the 48×40 GMA, 48×48, and EUR/EPAL pallets.

Step by step

How to calculate TI and HI

  1. Measure the case. Record the length, width, and height of one packed case.
  2. Cases per layer (TI). Divide the pallet length and width by the case footprint in both orientations and take the higher count.
  3. Layers (HI). Subtract pallet height from your max load height, divide by case height, and round down.
  4. Check the weight. Make sure TI × HI × case weight stays within your pallet weight limit.
  5. Total = TI × HI. Cases per layer times layers gives total cases per pallet.
Total cases = TI (per layer) × HI (layers)
Reference

Standard pallet sizes

PalletDimensionsAreaNotes
GMA (US standard)48 × 40 in1,920 in²Most common; fits standard trucks
Square48 × 48 in2,304 in²~20% more area; good for square cases
EUR / EPAL1200 × 800 mm (~47 × 31 in)~1,488 in²European standard

Height & weight limits

DestinationMax height (incl. pallet)Notes
Walmart60 inTI×HI must be declared on the GS1-128 label
Amazon FBA72 in non-stackable / 48 in stackableTI×HI declared in Seller Central
Typical max load weight~2,200–2,500 lbVaries by pallet, carrier & lane
Stacking patterns

Column vs interlocked stacking

Column (block) stackingCases sit directly on top of each other with corners aligned. This preserves the box’s full compression strength — best for heavy stacks — but layers have no interlock, so the load can shift under braking or cornering unless wrapped.
Interlocked (brick) stackingCases are rotated layer to layer so they tie the load together for better stability, but this reduces effective box compression strength by roughly 40–50%. Often used for lighter, sturdier cases.

The optimizer above uses a column-stack estimate (the strongest, most predictable pattern) and you can stabilize it with stretch wrap, corner boards, or glue dots.

Worked example

Pallet stacking example

You ship 12 × 10 × 8 in cases weighing 20 lb on a 48 × 40 GMA pallet, with a 60 in height limit and a 5.5 in pallet. Each layer holds 16 cases (4 × 4 = TI 16), and you can stack 6 layers high (HI 6), for 96 cases per pallet at 100% footprint use — a perfect fit.

Shipping 500 cases? At 96 per pallet you need 6 pallets (500 ÷ 96, rounded up).

Why it matters

Pallet utilization saves real money

Footprint utilization is the share of the pallet covered by cases. Higher is better: above ~90% is excellent, 75–90% is good, and below that wastes space and money. Improving utilization from 70% to 90% can cut your pallet count by around 22% — on a 100-pallet shipment that is roughly 22 fewer pallets and meaningful freight savings per truckload. Getting TI×HI right also keeps you compliant: Walmart, Target, and Amazon require the declared TI×HI to match the actual build, or you risk a chargeback.

Key terms

Pallet glossary

TI (tier)Number of cases on one layer of the pallet.
HI (high)Number of layers stacked on the pallet.
Cases per palletTI × HI — the total case count.
GMA palletThe 48 × 40 in US standard pallet.
Footprint utilizationShare of pallet area covered by cases.
Column stackingAligned stacking; maximum compression strength.
InterlockingRotated layers for stability; less strength.
OverhangCases extending past the pallet edge (avoid).
GS1-128The pallet label barcode that carries TI×HI.
FAQ

Pallet stacking FAQ

How many boxes fit on a pallet?
It depends on box and pallet size. On a 48×40 GMA pallet, 12×12 in boxes fit about 12 per layer, 6×6 in items about 48 per layer, and 24×18 in cases about 4 per layer. Multiply cases per layer by the layers that fit under your height and weight limits for the total.
What is TI-HI?
TI (tier) is the number of cases on one layer; HI (high) is the number of layers. TI × HI is the total cases per pallet — for example TI 16 × HI 6 = 96 cases.
How do you calculate TI and HI?
For TI, divide the pallet footprint by the case footprint in both orientations and take the higher count. For HI, subtract pallet height from max load height, divide by case height, and round down — then check the weight limit.
What is a standard pallet size?
The North American standard is the GMA pallet at 48×40 in (1,920 in²). A 48×48 square pallet has about 20% more area. The European EUR/EPAL standard is 1200×800 mm (~47×31 in).
What is the maximum pallet height?
It varies. Walmart typically allows 60 in including the pallet; Amazon FBA allows up to 72 in non-stackable and 48 in stackable. Always confirm the limit for your destination.
What is the maximum weight for a pallet?
A typical limit is around 2,200–2,500 lb, but it depends on the pallet, carrier, and lane. Set your own limit in the optimizer and it caps the layers to stay within it.
Is column or interlocked stacking better?
Column stacking keeps full box compression strength but can shift sideways; interlocking ties the load together for stability but cuts compression strength by ~40–50%. Many shippers column-stack and add stretch wrap or glue dots.
How many pallets do I need for my order?
Divide total cases by cases per pallet and round up — for example 500 cases at 96 per pallet needs 6 pallets. The optimizer does this when you enter your order quantity.
What is pallet footprint utilization?
The share of the pallet area covered by cases per layer. Above ~90% is excellent; 75–90% good. Improving from 70% to 90% can cut pallet count by ~22% and lower freight cost.
Why do retailers require TI-HI on labels?
Walmart, Target, and Amazon require TI×HI on the pallet label so receiving can verify the build. If your pallet does not match the declared TI×HI, you can get a compliance chargeback.
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