Load planning
Pallet Calculator and TI-HI Planner
This planner tests carton floor orientations, then applies pallet height and weight limits to a deterministic column pattern. TI = cartons per layer. HI = the smaller of height-limited layers and weight-limited layers. It follows a cited CHEP source record captured 2026-08-12.
Plan cartons per layer, layers high, finished load, weight limits, utilization, and a visual pattern.
Enter shipment details
Planning result
16 TI x 7 HI = 112 cartons per pallet
- Finished height
- 61.5 in
- Loaded weight
- 2,275 lb
- Footprint use
- 100%
- Pallets for quantity
- 1
Best deterministic column arrangement found. Review stability, support, compression, securement, and warehouse rules.
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What this calculator returns
Use this pallet calculator to estimate cartons per layer, layers high, finished pallet height, loaded weight, and pallets required. It is intended for warehouse planners, manufacturers, and shippers comparing a simple column-stacked TI-HI pattern against pallet dimensions, height limits, and weight limits before a physical stacking and stability review.
How this is calculated
The planner tests the carton footprint in its entered orientation and, when enabled, at a 90-degree floor rotation. For each orientation it uses whole-carton counts across the pallet width and along the pallet length. The orientation with the greatest cartons per layer becomes TI. HI is limited by both available load height and maximum loaded weight.
Finished height includes the pallet base. Loaded weight includes the pallet tare and every carton placed in the calculated full-layer stack. The number of pallets required is the entered carton quantity divided by cartons per pallet and rounded up.
TI = cartons per layer. HI = the smaller of height-limited layers and weight-limited layers.
Variable definitions
- TI
- The whole number of cartons placed on one pallet layer in the selected column pattern.
- HI
- The number of full layers allowed by the lower of the height and weight limits.
- Hmax
- Maximum loaded pallet height, including the pallet base.
- Wmax
- Maximum loaded pallet weight, including pallet tare.
Worked example
A 12 by 10 inch carton footprint fits four cartons along a 48 inch pallet direction and four along a 40 inch direction. The simple column result is 16 cartons per layer, so TI is 16. With an 8 inch carton and a 5.5 inch pallet base, a 72 inch height limit allows eight full layers.
At 20 pounds per carton, eight layers contain 128 cartons and weigh 2,560 pounds before pallet tare. Because the default 2,500 pound limit is lower, weight reduces HI to seven layers. The result is 16 TI by 7 HI, or 112 cartons, plus the stated pallet tare.
How to interpret the result
The visual shows a deterministic rectangular column pattern, not every possible mixed-orientation or interlocked pattern. A lower footprint percentage can identify unused deck area, but improving area use is not automatically safe if cartons lack edge support or compression strength.
Confirm the pallet specification and handling environment. A nominal 48 by 40 inch pallet can differ in design and rated performance. Racking, conveyor use, forklift handling, dynamic movement, and static floor stacking impose different conditions.
What to measure
Use the outside packaged dimensions as the shipment will be tendered. Include pallets, skids, cartons, wrapping, overhang, and projections. Weigh the complete packaged unit, not only its contents. When pieces differ, create a separate row or calculation for each size and weight combination.
Assumptions and limitations
The result is the best arrangement found by this deterministic planner. Stability, compression, interlock, edge support, load securement, and warehouse rules still require review.
- It does not calculate carton compression, stack stability, interlock strength, edge support, or product damage risk.
- It does not design mixed-SKU layers or allow cartons to overhang the pallet.
- It does not certify pallet capacity, warehouse rack capacity, trailer loading, or cargo securement.
- Pallet dimensions, tare, height, and weight limits are planning inputs that must match the actual equipment and rules.
Rules and sources used
Frequently asked questions
What do TI and HI mean?
TI is cartons per layer. HI is the number of layers high. TI multiplied by HI gives cartons per full pallet in the planned pattern.
Does the calculator try interlocked patterns?
No. It tests simple rectangular column orientations. Interlocked or mixed-orientation patterns may differ and require a stability and support review.
Does pallet height include the pallet?
Yes. Finished height includes the selected pallet base height plus the height of every calculated carton layer.
Can I rely on the weight limit as pallet capacity?
No. The entered limit is a planning constraint. Confirm the actual pallet design, condition, load distribution, rack arrangement, and supplier rating.