Pallet Optimization and Layer Configurations: Calculating Ti-Hi and Case Counts

The number of cases in a shipment or order.

Case Count is the number of cases in a shipment or order, and it becomes especially important when warehouse teams calculate how many cartons can fit on a pallet, in a trailer, or in a storage location. In pallet optimization, case count is usually tied to a Ti-Hi configuration: Ti means the number of cases per layer, and Hi means the number of layers stacked high. Multiplying Ti by Hi gives the total case count per pallet, which helps teams plan picking, replenishment, shipping, labor, and space utilization.

For example, if a pallet is built 10 Ti and 6 Hi, the pallet contains 60 cases. If a customer orders 600 cases, the warehouse can estimate 10 full pallets before considering partial pallets, weight limits, pallet height restrictions, or mixed-SKU requirements. This simple math is used every day in fulfillment centers, distribution warehouses, grocery logistics, beverage operations, CPG distribution, and manufacturing warehouses.

Ti-Hi And Case Count Basics

A Ti-Hi pattern describes how cases are arranged on a pallet. Ti, short for tier, refers to the number of cases placed on one horizontal layer. Hi, short for high, refers to the number of layers stacked vertically. The basic formula is: pallet case count = Ti x Hi.

If a product has a Ti-Hi of 8 x 5, the pallet holds 40 cases. If the Ti-Hi is 12 x 4, the pallet holds 48 cases. These calculations seem simple, but the correct configuration depends on case dimensions, pallet size, product weight, crush strength, trailer height, racking clearance, and whether the product can be safely stacked.

In the United States, many operations use a standard 48 x 40 inch GMA-style pallet, although other pallet sizes are common in certain industries. A case that measures 12 x 10 inches may fit very differently than a case that measures 18 x 14 inches. Rotating cases within a layer, using interlocking patterns, or changing case orientation can increase Ti and improve pallet cube utilization.

Core Formulas For Pallet Case Count

The most common calculation is straightforward: Ti multiplied by Hi equals the total number of cases on a pallet. A 9 Ti and 7 Hi pallet has a case count of 63. A 6 Ti and 8 Hi pallet has a case count of 48. Once the pallet case count is known, operations teams can calculate how many pallets are needed for a shipment.

The next formula is: total pallets needed = total order case count divided by cases per pallet. Since warehouses cannot usually ship a fraction of a pallet as a full pallet, teams round up when planning pallet positions. If an order contains 250 cases and each pallet holds 60 cases, the shipment requires four full pallets for 240 cases plus one partial pallet for the remaining 10 cases, or five pallet positions if the partial cannot be combined with other product.

For warehouse slotting and storage, another useful calculation is pallet cube. Pallet cube is the volume occupied by the palletized load, often calculated as length x width x height. If a pallet footprint is 48 x 40 inches and the loaded height is 60 inches, the pallet cube is 115,200 cubic inches, or about 66.7 cubic feet. Higher cube utilization means more product is stored or shipped in the same space, but only if the load remains stable and compliant with facility rules.

How Layer Patterns Affect Cube Utilization

Layer configuration can significantly change case count. A case may fit only 8 per layer if every carton faces the same direction, but 10 per layer if the pattern alternates orientations. Warehouse engineers, packaging teams, and WMS configuration specialists often test several layouts to find the best balance of density and stability.

Cube utilization is not just about filling the pallet footprint. It also includes the vertical space available in storage racks, trailers, containers, and automated systems. A pallet that is 70 inches high may maximize cases per pallet, but it may be too tall for a rack opening, conveyor clearance, stretch wrap equipment, or a customer receiving requirement. In that case, a lower Hi may be operationally better even if it reduces the pallet case count.

• Footprint utilization: Measures how much of the pallet surface is covered by cases on each layer.
• Vertical utilization: Measures how well the stacked load uses available height without exceeding restrictions.
• Cube utilization: Combines length, width, and height to evaluate total space efficiency.
• Trailer utilization: Looks at how pallet dimensions, weight, and stacking rules affect total loaded capacity.

Weight Distribution And Load Stability

A high case count is only valuable if the pallet can move safely through the operation. Heavy product stacked too high can create tipping risk, damage bottom layers, or exceed pallet capacity. Light but bulky products may cube out a trailer before reaching weight capacity, while dense products may weigh out before all available space is used.

Weight distribution should be even across the pallet deck. Uneven stacking can cause leaning, broken cases, stretch wrap failure, and unsafe forklift handling. When possible, heavier cases should form lower layers, and the load should stay within the pallet footprint with little or no overhang. Overhang can weaken cartons and create problems in racking, trailer loading, and automated handling equipment.

Interlocking patterns can improve stability by tying layers together, but they may reduce compression strength for some carton designs. Column stacking, where cases are aligned directly above one another, often provides better vertical strength because carton corners line up. The best choice depends on the product, packaging design, shipment distance, and handling environment.

Practical Ti-Hi Example

Assume a warehouse ships a SKU packed in cases measuring 16 inches long, 10 inches wide, and 8 inches high. The operation uses a 48 x 40 inch pallet and has a maximum loaded pallet height of 56 inches, including a 6-inch pallet. That leaves about 50 inches for product height. Since each case is 8 inches high, the maximum Hi is 6 layers, because 6 x 8 equals 48 inches of product height.

Next, the team calculates Ti. One possible layer pattern may fit 12 cases on the 48 x 40 pallet footprint by combining case orientations. With a Ti of 12 and a Hi of 6, the pallet case count is 72 cases. If the order is 1,000 cases, the warehouse can plan 13 full pallets containing 936 cases and one partial pallet containing 64 cases.

This calculation gives operations a planning baseline. The shipping team can estimate pallet positions, the inventory team can confirm available stock, and the transportation team can check whether the trailer has enough floor space and weight capacity. If the product is heavy, the final load plan may require fewer layers or more pallets to stay within safety and carrier limits.

Common Mistakes When Calculating Case Count

One common mistake is using theoretical fit instead of operational fit. A spreadsheet may show that cases fit perfectly on a pallet, but real cartons can bulge, labels may need to face outward, and pallet boards may not be perfectly square. Small dimensional differences can reduce the actual Ti or create unstable loads.

Another mistake is ignoring customer or carrier requirements. Some retailers specify maximum pallet heights, exact Ti-Hi configurations, label placement, or whether pallets can be double stacked. A pallet that is efficient for the warehouse may be rejected or reworked at the receiving dock if it does not match the customer’s routing guide.

• Not checking carton strength: Bottom cases may crush if the Hi is too aggressive for the packaging.
• Ignoring pallet weight limits: Pallets, racks, forklifts, and trailers all have weight constraints.
• Forgetting partial pallets: Order case count rarely divides perfectly into full pallet quantities.
• Using one pattern for every SKU: Different case sizes and weights require different Ti-Hi calculations.

How WMS And Planning Tools Use Case Count

A warehouse management system can store standard Ti-Hi values for each SKU and use them during receiving, putaway, replenishment, picking, and shipping. When the WMS knows that a full pallet contains 72 cases, it can recommend pallet picks for large orders and case picks for smaller quantities. This improves labor planning and reduces manual calculation at the dock.

Transportation planning tools also use pallet case count to estimate load plans. If a trailer holds 26 standard pallet positions and each pallet holds 72 cases, the theoretical trailer case count is 1,872 cases before considering weight, axle limits, pallet stacking, and load sequencing. For high-volume shippers, accurate Ti-Hi data helps reduce underutilized trailers and unnecessary freight cost.

Accurate master data is critical. If the Ti-Hi in the system is wrong, inventory may appear to require fewer pallet positions than it actually does. That can lead to short storage space, missed appointments, rework, detention, and inaccurate freight quotes.

Best Practices For Better Pallet Optimization

Start with verified case dimensions and weights, not estimates. Measure the actual shipping carton after it is packed and sealed. Include bulge, handles, seams, and any features that affect pallet fit. For new products, test physical pallet builds before assigning a final Ti-Hi in the WMS or customer setup file.

Balance density with safety. Maximizing case count should not create unstable pallets, crushed product, or unsafe lift truck moves. Review pallet height restrictions, product fragility, wrapping standards, and receiving requirements before approving a configuration.

Document standard Ti-Hi patterns by SKU and share them across purchasing, packaging, warehousing, and transportation teams. When case dimensions change, update the pallet pattern immediately. Even a one-inch change in carton size can lower the Ti, reduce pallet case count, and increase transportation cost.

In short, the case count is more than a number on an order; it is a core input for pallet design, warehouse capacity, trailer planning, and shipping efficiency. By using Ti-Hi calculations, checking cube utilization, and respecting stability and weight limits, logistics teams can build pallets that are dense, safe, and practical to move through the supply chain.