Introduction
The Pallet Configuration Calculator works out how to stack boxes or drums on a pallet. You type in your box size, weight, and pallet type. It returns how many units fit in each layer (TI), how many layers you can stack (HI), and the total number of units per pallet.
It checks three big limits for you: stack height, total weight, and overhang past the pallet edge. Green means pass, orange means you are close to a limit, and red means you went over. You can try column, brick, pinwheel, or hybrid stacking patterns and compare them side by side.
You also get a 3D view of the loaded pallet, top-down layer diagrams drawn to scale, charts, and a step-by-step math breakdown. Switch between inches and pounds or millimeters and kilograms at any time. When you find the setup you like, export it as a CSV file.
Use it to plan shipments, cut freight cost, fill trucks better, and keep loads safe and stable.
How to use our Pallet Configuration Calculator
Enter your box or drum size, its weight, and your pallet limits. The calculator shows how many units fit per layer (TI), how many layers fit (HI), total units, stack height, total weight, and 3D and top-down load diagrams.
Unit system: Pick Imperial (in/lbs) or Metric (mm/kg). Every value you typed is converted for you.
Package type: Choose Box for square cases or Drum for round containers.
Case length, width, and height: Type the size of one box. Each field has its own unit menu.
Drum diameter and height: If you picked Drum, enter how wide across and how tall it is.
Weight per unit: Enter the weight of one full box or drum.
Units per carton: Enter how many items are inside one case. This gives you a total "eaches" count.
Orientation lock: Choose which way units may sit. Pick "Upright only" if the box must stay this side up.
Single-unit preview: Click H up, L up, or W up to see one unit in 3D. This only changes the picture, not the math.
Pallet standard: Pick a common pallet like GMA 48×40 or Euro 1200×800. Choose Custom to set your own.
Pallet length and width: Enter the deck size of your pallet if you are not using a preset.
Pallet deck height: Enter how tall the empty pallet is. This is added to the load height.
Pallet tare weight: Enter the weight of the empty pallet.
Max stack height: Enter the tallest the loaded pallet may be, pallet included. Truck and rack rules often set this.
Max total loaded weight: Enter the heaviest the full pallet may be.
Units per layer (TI) mode: Choose Auto-optimize to let the tool find the best fit, or Set manually to force a number.
Units per layer (manual): Type your own count per layer. This only works in manual mode.
Overhang allowance per side: Pick how far boxes may hang past the pallet edge. Pick 0 for no overhang.
Stacking pattern: Choose Column, Interlocking (Brick), Pinwheel, or Hybrid to test them all.
Layer alignment: Choose how each new layer sits on the one below, such as Parallel, Mirror, or Rotate 180°.
Number of layers (HI): Drag the slider or type a number. The tool caps it at your height and weight limits.
Load accessories: Tick edge boards, corner boards, a do-not-stack cone, or stretch wrap. Their weight is added to the total.
Straps along length and width: Pick how many straps you use in each direction.
Calculate and Reset: Click Calculate to run the numbers, or Reset to go back to the sample values.
Results options: Switch display units, tick Compare on up to three configurations, and click Export results (CSV) to save your pallet plan.
What Is Pallet Configuration?
Pallet configuration is the plan for how boxes, cartons, or drums sit on a pallet. It tells you how many units go in one layer, how many layers to stack, and how the units should be turned. A good pattern keeps the load tight, safe, and cheap to ship. A bad pattern wastes space, tips over, or crushes product.
TI and HI: The Two Key Numbers
Warehouse teams use two short words for pallet loads:
- TI is the number of units in one layer (also called cases per tier).
- HI is the number of layers stacked on the pallet.
Multiply them and you get the full pallet count: TI × HI = total cases per pallet. If each case holds smaller items, multiply again by the units per carton to get total eaches.
Common Pallet Sizes
| Pallet | Size | Where It Is Used |
|---|---|---|
| GMA / US Standard | 48 × 40 in | North America, grocery and retail |
| Euro (EUR1) | 1200 × 800 mm | Europe |
| UK / Industry | 1200 × 1000 mm | UK and general industry |
| Asia Standard | 1100 × 1100 mm | Japan and much of Asia |
| Australian | 1165 × 1165 mm | Australia |
| Half Pallet | 800 × 600 mm | Store displays, small loads |
Stacking Patterns
- Column stack: every box sits straight above the one below. This is the strongest way to hold weight, because box corners carry the load. It can slide apart without wrap or straps.
- Interlocking (brick): rows are turned and offset like bricks in a wall. The layers lock together, so the load is more stable, but each box loses some stacking strength.
- Pinwheel: four units turn around a center gap. It is helpful when box sizes leave odd space on the pallet.
- Hybrid: test every pattern and compare the results before you pick one.
Limits You Must Respect
Three limits decide how tall a pallet can go:
- Height: most truck trailers and warehouse racks cap loads near 96 in (about 2440 mm), including the pallet deck.
- Weight: a common cap is 2,000 to 2,500 lbs (about 900 to 1,130 kg) per pallet. Racks, forklifts, and the pallet itself all have limits.
- Overhang: boxes that hang past the pallet edge lose strength fast. Even 1 in of overhang can cut stack strength by roughly a third. Many shippers allow zero overhang; some allow 1 in per side.
Surface Usage and Cube Utilization
Surface usage shows how much of the pallet deck a layer covers. Cube utilization shows how much of the total load space you fill, from the deck up to your height limit. Higher numbers mean fewer pallets, fewer trucks, and lower freight cost. Most loads waste space because of empty gaps between boxes and unused height near the top.
Why It Matters
Freight is often billed by pallet spot or by cubic space. Adding one more layer or one more box per layer can cut your cost per unit across every shipment for the year. Better patterns also mean fewer damaged goods, safer forklift handling, and fewer returns from crushed cartons.
Simple Tips
- Design the box size around the pallet, not the other way around. Boxes that divide evenly into 48 × 40 in or 1200 × 800 mm pack the best.
- Put the heaviest, strongest cases on the bottom layers.
- Use column stacks for heavy or weak boxes, and interlock for light, sturdy ones.
- Add corner boards and stretch wrap when a load is tall or the pattern has gaps.
- Keep the load square with the pallet edge so racks and trailers load clean.