Pallet Calculator

On This Page

• How to use this calculator
• Pallet Ti Hi: what the numbers mean
• Standard pallet sizes and configurations
• How to calculate boxes per pallet step by step
• Pallet volume and cube
• Worked examples
• Frequently asked questions
• References

How to Use This Calculator

Enter your box length, width, and height using the same unit you measure in (inches, centimeters, or millimeters). Select a pallet size from the dropdown: US GMA 48×40 in, Euro EUR-1, ISO A, or a custom size you enter directly. Set the maximum stack height (the total height limit from the floor, pallet included) and the pallet board height (the height of the pallet deck itself).

The palletization calculator tests all six possible box orientations and picks the one that puts the most boxes on the pallet. It returns TI (boxes per layer), HI (number of layers), and total boxes, along with pallet volume in cubic feet for freight planning. The layer layout preview shows the top-layer grid so you can see how the boxes sit on the pallet.

Switching units converts all entered values automatically. Change from inches to centimeters and every dimension scales across, so you never need to re-enter numbers manually.

For spherical products, the Sphere Packing Calculator handles circular footprints and void space calculations that this pallet configuration calculator is not designed for.

Pallet Ti Hi: What the Numbers Mean

TI stands for "tier" and means the number of boxes in a single horizontal layer on the pallet surface. HI stands for "high" and is the number of layers stacked on top of each other from the pallet deck to the maximum allowed height. Together, TI × HI gives the total carton count per pallet, the standard measure used in warehousing, purchase orders, and shipping contracts worldwide.

You will find TI and HI on most retail pallet labels. A label reading "TI: 8, HI: 5" means 8 boxes per layer, 5 layers, 40 boxes total on that pallet. Grocery distribution centers, Amazon FBA, and big-box retail receiving departments all require Ti Hi labels on inbound pallets. Getting these numbers wrong results in rejected shipments and costly repalletizing fees.

The pallet Ti Hi calculator automates this. Enter the box dimensions and pallet size, and it returns both values instantly along with the best box orientation.

Why orientation matters

A box can sit on a pallet in six different orientations (three unique faces, each rotatable 90 degrees). The orientation that gives the highest TI does not always give the highest total, because the layer height changes with orientation. Here's why this matters: a 12×10×8 inch box on a 48×40 pallet with 60 inches total height produces different results depending on which face is on the pallet floor.

• 12×10 footprint, 8 tall: TI = 4×4 = 16, HI = floor(54.5/8) = 6, total = 96
• 8×10 footprint, 12 tall: TI = 6×4 = 24, HI = floor(54.5/12) = 4, total = 96
• 12×8 footprint, 10 tall: TI = 4×5 = 20, HI = floor(54.5/10) = 5, total = 100

The third orientation wins with 100 boxes. The pallet stacking calculator finds this automatically without you needing to test each option by hand.

Standard Pallet Sizes and Configurations

US GMA: 48 × 40 inches

The Grocery Manufacturers Association (GMA) pallet is the North American standard. Nearly every US warehouse, truck trailer, and loading dock is designed around this 48×40 inch footprint. A standard 53-foot dry van trailer holds 26 GMA pallets in a double row. The GMA pallet deck is typically 5.5 inches tall and rated for 2,500 lb dynamic load.

Euro EUR-1: 1200 × 800 mm

The European standard for grocery and general merchandise. Required by most major European retailers. The EUR-1 footprint is narrower than the GMA, which affects TI for boxes wider than about 400 mm. A standard European 13.6-meter trailer holds 33 EUR-1 pallets. The deck height is approximately 144 mm.

ISO A: 1200 × 1000 mm

Common in automotive, chemical, and pharmaceutical supply chains across Europe and Asia. Slightly wider than EUR-1 and closer to the GMA footprint when converted. ISO A pallets fit 11 per 20-foot shipping container and 23 per 40-foot container.

Custom pallet dimensions

Half pallets (48×20 in) are standard in pharmacy and club retail. Slip sheets replace pallets in some high-density container loads. Enter any pallet length and width in the Custom option. The pallet size calculator handles any footprint, not just the three standard presets.

For ocean freight, carriers quote in CBM (cubic meters). The pallet dimension calculator returns volume in cubic feet; multiply by 0.0283168 to convert to CBM.

How to Calculate Boxes Per Pallet Step by Step

The pallet loading calculator uses four steps. All division results are rounded down (floor) because partial boxes do not fit.

Step 1: Subtract the pallet board height

Available stacking height = max stack height − pallet board height. A 60-inch total limit with a 5.5-inch GMA pallet deck gives 54.5 inches of usable space for boxes. Skipping this step overestimates HI by one layer in most practical cases.

Step 2: Try all six box orientations

For each orientation, calculate TI and HI using the formulas above, then multiply to get the total. The orientation with the highest total wins. When two orientations tie on total, the one with more boxes per layer (higher TI) is preferred because lower, wider stacks are more stable.

Step 3: Check the result against physical constraints

The calculator finds the mathematical optimum. In practice, box stacking stability, label orientation, fragile goods, and weight distribution can override the optimal configuration. A taller box height per layer (higher fH) can make a pallet top-heavy. Always confirm with your warehouse team before committing to a new pallet configuration in a purchasing system.

For cost analysis at different order volumes, the Break Even Point Calculator helps model how packaging and palletizing costs affect your unit economics. And use the Product Pricing Calculator to factor freight and palletizing cost per unit into your selling price once you know how many units ship per pallet.

Pallet Volume and Cube

Pallet volume is the full rectangular space the pallet load occupies from floor to maximum stack height: pallet length × pallet width × stack height. For a US GMA pallet at 60 inches: 48 × 40 × 60 = 115,200 in³ = 66.67 ft³. Carriers use pallet volume to calculate dimensional weight and trailer space allocation.

Pallet cube (also called cargo cube) is the total volume of all boxes on the pallet: box volume × total boxes. If TI×HI = 100 boxes each measuring 12×10×8 in, pallet cube = 100 × 960 = 96,000 in³ = 55.56 ft³.

Used space percentage = pallet cube ÷ pallet volume × 100. A result of 83% means 17% of the pallet space is air, gaps between boxes and around the pallet perimeter. Improving box dimensions to reduce gaps can meaningfully lower freight cost per unit at scale.

The pallet cube calculator output in cubic feet maps directly to LTL freight density calculations. Freight density = total pallet weight (lb) ÷ pallet volume (ft³). Use the density figure with the NMFC table to determine freight class. Higher density means lower class and lower rates, which is why optimizing pallet loading with a palletizing calculator pays off in real shipping costs.

For tank and container volume comparisons, the Tank Volume Calculator handles any rectangular space in liters, gallons, and cubic feet.

Worked Examples

Example 1: Standard grocery case on a GMA pallet

A grocery brand ships cases measuring 14 × 11 × 9 inches on GMA pallets (48 × 40 in) with a 60-inch max height and 5.5-inch pallet deck.

1. Available height = 60 − 5.5 = 54.5 in.
2. Try 14×11 footprint, 9 tall: TI = floor(48/14) × floor(40/11) = 3 × 3 = 9. HI = floor(54.5/9) = 6. Total = 54.
3. Try 11×9 footprint, 14 tall: TI = floor(48/11) × floor(40/9) = 4 × 4 = 16. HI = floor(54.5/14) = 3. Total = 48.
4. Try 14×9 footprint, 11 tall: TI = floor(48/14) × floor(40/9) = 3 × 4 = 12. HI = floor(54.5/11) = 4. Total = 48.
5. Best: TI 9, HI 6 = 54 cases per pallet.

Example 2: Euro box on a Euro pallet

A German distributor ships cartons of 30 × 20 × 15 cm on EUR-1 pallets (120 × 80 cm) with 180 cm max height and 15 cm pallet board.

1. Available height = 180 − 15 = 165 cm.
2. Try 30×20 footprint, 15 tall: TI = floor(120/30) × floor(80/20) = 4 × 4 = 16. HI = floor(165/15) = 11. Total = 176.
3. Try 20×15 footprint, 30 tall: TI = floor(120/20) × floor(80/15) = 6 × 5 = 30. HI = floor(165/30) = 5. Total = 150.
4. Best: TI 16, HI 11 = 176 boxes.

Example 3: Half pallet for pharmacy retail

A pharmacy retailer uses 48 × 20 inch half pallets. Box size: 10 × 8 × 6 inches. Max height 48 inches, pallet deck 4 inches.

1. Available height = 48 − 4 = 44 in.
2. Try 8×6 footprint, 10 tall: TI = floor(48/8) × floor(20/6) = 6 × 3 = 18. HI = floor(44/10) = 4. Total = 72.
3. Try 6×8 footprint, 10 tall: TI = floor(48/6) × floor(20/8) = 8 × 2 = 16. HI = 4. Total = 64.
4. Try 10×8 footprint, 6 tall: TI = floor(48/10) × floor(20/8) = 4 × 2 = 8. HI = floor(44/6) = 7. Total = 56.
5. Best: TI 18, HI 4 = 72 boxes on the half pallet. Custom pallet input handles this directly.

Example 4: How many pallets for a production run

A factory produces 1,440 units per run. Each unit ships in a carton of 16 × 12 × 10 inches on a GMA pallet (60 in max height, 5.5 in deck).

1. Available height = 54.5 in.
2. Best orientation: 16×10 footprint, 12 tall. TI = floor(48/16) × floor(40/10) = 3 × 4 = 12. HI = floor(54.5/12) = 4. Total = 48 cartons per pallet.
3. Pallets needed = ceiling(1440 ÷ 48) = 30 pallets.
4. A 53-foot trailer holds 26 GMA pallets, so this shipment requires 2 trucks.

Example 5: Pallet cube for freight class calculation

A pallet holds 60 boxes, each 14 × 10 × 8 inches, total pallet weight 480 lb. Pallet size GMA at 60 in max height.

1. Pallet volume = 48 × 40 × 60 = 115,200 in³ = 66.67 ft³.
2. Box volume = 14 × 10 × 8 = 1,120 in³ per box.
3. Pallet cube = 60 × 1,120 = 67,200 in³ = 38.89 ft³.
4. Used space = 38.89 ÷ 66.67 = 58.3%.
5. Freight density = 480 lb ÷ 66.67 ft³ = 7.2 lb/ft³ → NMFC Class 100.

Frequently Asked Questions

How do I calculate how many cartons fit on a pallet?

Use the Ti Hi formula: TI = floor(pallet length ÷ box length) × floor(pallet width ÷ box width). HI = floor(available height ÷ box height). Total cartons = TI × HI. Test all six box orientations and use the one that gives the highest total. This pallet calculator does that automatically.

How do you calculate Ti Hi for a pallet?

Ti is the number of boxes in a single layer on the pallet surface. Hi is the number of layers from the pallet deck to the maximum allowed height. Multiply them: Ti × Hi = total boxes. Standard pallet labels show both numbers so warehouse staff can verify pallet loads without counting. Getting Ti Hi wrong causes rejected shipments at retail distribution centers.

How many cases fit on a standard GMA pallet?

It depends on case size. A 12 × 10 × 8 inch case on a 48 × 40 GMA pallet at 60 inches max height fits 96 to 100 cases depending on orientation. A smaller 10 × 8 × 6 inch case can fit 150 or more. Enter your exact case dimensions in the pallet stacking calculator above for the precise result.

How many pallets fit in a 53-foot trailer?

A 53-foot dry van trailer holds 26 GMA pallets in a standard double-row straight layout (two pallets abreast at 48 inches each = 96 inches across the 98-100 inch interior width). Some carriers fit 28 to 30 pallets using a pinwheel or turned configuration where pallets alternate direction.

How many pallets fit in a 20-foot container?

Approximately 8 to 11 GMA pallets in a 20-foot container, depending on arrangement. A single straight row fits 8 (4 deep × 2 abreast). A turned or pinwheel layout can reach 10 to 11. EUR-1 pallets fit 11 per 20-foot container in a standard layout.

How many pallets fit in a 40-foot container?

Approximately 18 to 22 GMA pallets. A standard layout gives 18 (9 rows × 2 abreast). A pinwheel configuration reaches 20 to 22. EUR-1 pallets fit 23 to 25 depending on arrangement and container type (standard vs. high-cube).

How do you calculate pallet cube?

Pallet cube = box volume × total boxes on pallet. Box volume = length × width × height. Express in cubic feet by dividing in³ by 1,728, or in CBM by multiplying ft³ by 0.0283168. Freight brokers use pallet cube to quote space on trucks and ships and to calculate density-based freight class.

How do you calculate pallet density for freight class?

Freight density = total pallet weight (lb) ÷ pallet volume (ft³). For a GMA pallet at 60 in: volume = 66.67 ft³. A 500 lb pallet has density 7.5 lb/ft³. Use that figure with the NMFC density table to determine freight class. Lower class numbers (50, 55, 60) indicate denser freight with lower shipping rates per lb.

How do you calculate pallet volume in cubic feet?

Pallet volume = pallet length (in) × pallet width (in) × stack height (in) ÷ 1,728. For a GMA pallet at 60 in: 48 × 40 × 60 ÷ 1,728 = 66.67 ft³. In CBM multiply ft³ by 0.0283168: 66.67 × 0.0283168 = 1.888 m³. Use pallet volume to estimate truck and container space requirements.

What is the standard pallet board height?

A standard GMA pallet deck is 5.5 inches (139.7 mm) tall. Euro EUR-1 pallets are approximately 144 mm (5.67 inches). Enter your actual pallet height in the pallet board height field for accurate available stacking height. Using the wrong board height shifts HI by one layer in edge cases.

What is the difference between a pallet and a skid?

A pallet has a bottom deck (boards connecting the bottom of the feet) so forklifts can enter from all four sides. A skid has no bottom deck, allowing entry only from the two open sides. Skids were the original design; pallets became standard because four-way entry is faster in modern warehouses. The Ti Hi calculation works identically for both.

References

• FMI: The Food Industry Association (formerly GMA): North American standard pallet dimensions, weight limits, and deck configurations for grocery and general merchandise supply chains.
• ISO 6780:2003 Flat Pallets for Intercontinental Materials Handling: International standard covering pallet footprint dimensions including EUR-1 (1200×800 mm), ISO A (1200×1000 mm), and other global sizes used in cross-border logistics.
• NMFTA: National Motor Freight Traffic Association: NMFC density-based freight class guidelines used to calculate shipping rates for LTL palletized freight in North America.