Optimizing TI-HI: Improve Cube Utilization, Safety, And Retail Compliance

A pallet configuration measurement showing cases per layer, called TI, and the number of layers, called HI.

TI-HI A pallet configuration measurement showing cases per layer, called TI, and the number of layers, called HI. Optimizing TI-HI balances cube utilization, pallet stability, weight limits, and retailer rules to lower costs and reduce damage.

Warehouse managers and supply chain planners can often increase efficiency simply by re-evaluating TI-HI patterns. Small changes to case orientation or layer patterns can free up trailer space, reduce the number of pallets per shipment, or bring pallets into compliance with automated retail sorting systems. Below are practical optimization techniques and trade-offs to consider.

What Optimization Targets Look Like

• Higher Cube Utilization: Maximize cases per pallet and per trailer to reduce transportation cost per case.
• Safe Stackability: Ensure stacked pallets remain stable in transit and at the DC; stability often limits HI more than cube alone.
• Retail Compliance: Meet retailer height, overhang, and pattern rules to avoid chargebacks.

Practical Methods To Improve TI-HI

Start with SKU-level analysis. Test alternate cases orientations and stacking patterns in the warehouse before changing master packing specifications.

• Rotate Cases: Turning cases 90 degrees in a layer can sometimes change TI by adding an extra case across the footprint.
• Use Interlocking Patterns: Alternate case orientation between layers to improve stability and sometimes allow a taller HI safely.
• Reduce Void Space: Combine smaller SKUs into mixed pallets when retailer rules allow, to improve cube utilization instead of shipping partly filled pallets.

Trade-Offs To Evaluate

Optimizing TI-HI is a balance. Increasing TI may reduce HI due to weight limits. Pushing HI higher to reduce TPUs (truck pallets utilized) can compromise pallet stability. Always test patterns for damage risk during typical handling and transit conditions.

Tools And Data To Support Optimization

• Cube And Palletization Software: Use a palletization tool to model patterns and compute TI-HI recommendations and cube utilization metrics.
• WMS Integration: Capture actual TI-HI used in outbound builds to analyze variance against standard patterns and identify optimization opportunities.
• Field Testing: Build sample pallets, load into trailers, and evaluate handling and damage rates across routes.

Safety And Material Handling Considerations

Higher HI increases top-heaviness. Ensure forklift operators and pallet jacks handle tall pallets appropriately and that racks or trailers secure loads. Use strapping, stretch wrap, or slip sheets when necessary. Review OSHA and local warehouse safety guidance for stacking heights and floor load limits.

Cost And Carbon Impact

Better TI-HI often reduces the number of pallets and trailers needed, lowering transport cost and carbon emissions. When calculating cost benefits, include packaging changes, pallet repair/replacement, and potential retailer chargeback reductions in the ROI assessment.

Implementation Checklist

• Audit Current Patterns: Record TI-HI for high-volume SKUs over a representative period.
• Model Alternatives: Use palletization software to propose patterns that improve cube utilization without compromising safety.
• Pilot And Measure: Run small pilots, measure damage, receiving time, and any chargebacks, then scale successful patterns.

In short, the TI-HI configuration is the key lever for improving pallet cube utilization, reducing transport cost, and meeting retailer constraints. Optimization requires a data-driven approach: model patterns, pilot changes, measure outcomes, and institutionalize successful TI-HI standards across packing and WMS processes.