The Importance of Efficient Palletizing
Shipping empty air is expensive. Whether packing an LTL shipment or a full ocean container, the goal is to safely fit as much product as possible onto a standard pallet footprint without causing overhang or instability.
A poorly planned pallet not only wastes space, lowering cube utilization, but it can also collapse during transit if the structural integrity of the carton arrangement is weak.
Understanding Ti-Hi (Tie and High) Patterns
A pallet plan is typically expressed as a Ti-Hi number.
'Ti' (Tie) refers to the number of cartons or boxes arranged in a single layer on the pallet. 'Hi' (High) refers to the number of layers stacked vertically on the pallet.
For example, a Ti-Hi of 10 x 4 means there are 10 boxes per layer, stacked 4 layers high, resulting in 40 total boxes per pallet. Alternating the arrangement of the 'Ti' layer between tiers creates an interlocking pattern, significantly increasing load stability.
How to Calculate Pallet Cube Utilization
Cube utilization measures how effectively you are using the three-dimensional space available on the pallet, expressed as a percentage.
The Formula: (Total Volume of Cartons on Pallet) / (Usable Volume of the Pallet Footprint).
Example: A standard GMA pallet is 48" L x 40" W. If your max height is 50", the usable volume is 96,000 cubic inches. If your load consists of 30 cartons, each measuring 12" x 10" x 10" (1,200 cu in), the total carton volume is 36,000 cu in. The cube utilization is 36,000 / 96,000 = 37.5%. (This indicates a very poor load plan or a dense, heavy product that hits weight limits before volume limits).
Maximum Pallet Dimensions and Weight Limits
While optimizing space, planners must respect maximum limits. In North America, the standard GMA pallet is 48 by 40 inches. Cartons should strictly avoid overhang, as boxes hanging over the edge lose up to 30% of their compression strength and are prone to forklift damage.
Weight limits must also be considered. Most standard wooden pallets have a safe dynamic load capacity of roughly 2,500 lbs. Additionally, warehouse racking systems have strict weight limits per bay.
Frequently asked questions
What is standard pallet overhang?
Zero overhang is the standard. Any overhang compromises carton strength and risks damage during transit and racking. Some shippers allow up to 1/2 inch of overhang, but it is highly discouraged.
How high can I build a pallet?
Maximum height depends on the mode of transport and racking constraints. A typical LTL shipment maxes out around 96 inches. However, a common warehouse standard is 50 to 60 inches to allow for double-stacking in trailers and easy rack storage.
What is a standard GMA pallet dimension?
The Grocery Manufacturers Association (GMA) standard pallet in North America measures 48 inches in length by 40 inches in width.
Why alternate layers on a pallet?
Alternating or interlocking the carton pattern between layers ties the load together, preventing columns from splitting apart or toppling during cornering and transit vibrations.