Warehousing, Palletization & Material Handling

Pallet Stacking & Ti-Hi Utilization Calculator

Calculate pallet utilization (% volume efficiency) and Ti-Hi carton stacking patterns for standard 48x40 GMA pallets. Export free PDF packing diagrams.

1. Overview & Logistics Industry Significance

Palletization is the backbone of modern warehouse logistics and supply chain storage. Optimizing the arrangement of corrugated boxes on standard industrial pallets—specifically the North American 48 × 40 inch GMA pallet and European 1200 × 800 mm EUR pallet—directly impacts warehouse racking efficiency, prevents product crushing, and maximizes trailer cube utilization. The Ti-Hi calculation method dictates how many cartons fit per horizontal layer (Ti) and how many layers high the pallet can be stacked (Hi). Proper pallet optimization ensures structural integrity, avoids dangerous carton overhang, and eliminates freight damage during forklift handling and over-the-road transport.

2. How It Works & Calculation Rules

Ti-Hi Pallet Math: - Ti (Tie): The number of cartons placed in a single horizontal tier on the pallet base. - Hi (High): The total number of tiers/layers stacked vertically on top of each other. - Total Cartons Per Pallet = Ti × Hi. - Total Pallet Height = (Carton Height × Hi) + Pallet Base Height (standard GMA wood base is 5.5 to 6.0 inches). - Total Pallet Weight = (Carton Weight × Total Cartons) + Empty Pallet Weight (~40–45 lbs). Pallet Fit Constraints: - GMA Standard Pallet: 48 in (L) × 40 in (W). Max load height typically 72–84 inches for standard trailers. Max static weight 4,600 lbs. - Overhang Risk: Cartons extending beyond the pallet edge lose up to 32% of their compressive edge crush strength (ECT) and suffer severe shipping damage. - Underhang Waste: Excessive empty space on pallet edges wastes trailer cube space and causes loose shrink wrap shifts.

3. Step-by-Step Instructions

  1. Enter carton dimensions: Length, Width, Height (inches or cm) and individual unit weight.
  2. Specify maximum allowable pallet load height and maximum pallet gross weight capacity.
  3. Calculate optimal Ti (boxes per layer) and Hi (vertical layers) for 48x40 GMA pallets.
  4. Inspect total pallet box capacity, volume efficiency %, and gross pallet weight.

4. Practical Real-World Example

Stacking cartons measuring 16 × 12 × 10 inches and weighing 25 lbs onto a standard 48 × 40 inch GMA pallet (max height 60 inches): Fitting 10 boxes per layer (Ti = 10) in an interlocking layout, with 5 vertical layers (Hi = 5) yields 50 total cartons. Pallet freight height is 55.5 inches (50 in cargo + 5.5 in wood base) and gross weight is 1,290 lbs, operating at 94.2% surface area utilization with zero overhang.

Frequently Asked Questions (FAQ)

What does Ti-Hi mean in warehouse logistics?

Ti refers to "Tie" (the number of cartons loaded per horizontal layer on a pallet), while Hi refers to "High" (the number of vertical layers stacked). Ti multiplied by Hi equals total cartons per pallet.

What is the standard pallet size in North America?

The standard pallet size established by the Grocery Manufacturers Association (GMA) is 48 inches × 40 inches (1219 mm × 1016 mm).

Why is pallet overhang dangerous for freight?

When cartons hang over the edge of a wood pallet, the corrugated corners lose structural support from the pallet deckboards, reducing stacking strength by up to 30% and causing bottom boxes to crush under top weight.