Pallet-Optimized Carton Size Calculator
Enter the pallet, load, and carton constraints to size a carton backward from the exact number of cases you need on a full pallet. The result is the largest rectangular outer footprint at your preferred length-to-width proportion.
Maximum carton outer length14.63
- Maximum carton outer width
- 9.75
- Recommended TI-HI
- 12 TI × 5 HI
- Layer grid
- 3 × 4 (length × width)
- Loaded pallet height
- 55.5
- Product payload
- 900
- Pallet footprint utilization
- 89.12%
- Limiting constraint
- Pallet width
Dimensions are outer carton envelopes in inches. Leave a manufacturing tolerance before releasing a finished carton design.
How to use this calculator
- Enter the pallet deck dimensions and the edge clearance required by the warehouse or customer.
- Enter the exact case count, the finished carton height, and the loaded-height limit including the pallet.
- Choose the preferred outer length-to-width ratio and enter the expected gross carton weight.
- Review the TI-HI, layer grid, payload, and limiting constraint before allowing for manufacturing tolerance.
How the carton footprint is sized
TI is the number of cartons in one layer and HI is the number of layers. Their product must equal the target pallet count: target cases = TI × HI. The calculator tests every whole-number HI that divides the target and still fits within the loaded-height limit. This is the reverse of the usual TI-HI calculation, which starts with a carton size and counts what fits.
First it reserves clearance around the deck: usable length = pallet length − 2 × edge clearance and usable width = pallet width − 2 × edge clearance. For each factor pair A × B = TI, it tests cartons both lengthwise and rotated. With A cartons along the pallet length, B along the width, and preferred ratio R, the lengthwise case uses S = min(usable length ÷ (A × R), usable width ÷ B). The carton width is S and its length is R × S.
Each candidate must also satisfy pallet height + HI × carton height ≤ maximum loaded height and target cases × carton weight ≤ maximum payload. The selected result has the largest carton footprint. Equal footprints break first toward higher pallet-footprint utilization, then toward a lower loaded height.
What changes the result most
The target count determines which TI-HI factorizations are available. A count with several divisors can offer a broad, efficient layer and a useful number of layers; a prime count has few choices. Edge clearance reduces both usable dimensions, while a taller fixed carton can eliminate HI values. The preferred proportion matters too: a long narrow carton may fit a different grid than a nearly square one.
What this calculator leaves out
This is a geometric envelope for uniform, axis-aligned rectangular grids. It does not evaluate pinwheel or interlocking patterns, board thickness, bulging, load stability, compression strength, center of gravity, handling forces, racking, slip sheets, corner boards, stretch wrap, or carrier requirements. Pallet-loading research treats stability and transport forces as separate real-world constraints, so confirm the proposed carton and pattern with samples and load testing.
Worked example
For a 48 by 40 inch pallet with no edge clearance, 12 target cases, a 10 inch carton height, no pallet height, a 20 inch height limit, and a 2:1 preferred ratio, HI can be 1 or 2. Choosing HI 2 gives TI 6. A 2 by 3 layer has S = min(48 ÷ (2 × 2), 40 ÷ 3) = 12, so the maximum carton is 24 by 12 inches.
The load is 20 inches high. Its six 24 by 12 inch footprints use 1,728 of the pallet's 1,920 square inches, or 90% utilization. Any entered carton weight is then multiplied by 12 and must remain within the payload limit.
Common questions
What does TI-HI mean?
TI means the number of cartons in one tier or layer. HI means the number of layers high. Multiplying TI by HI gives the total case count on the pallet, such as 12 TI by 5 HI for 60 cases.
Why size a carton backward from a pallet count?
A required case count often comes from warehouse, retail, or transport planning. Working backward identifies the largest footprint at a chosen proportion that can support that exact count, rather than discovering later that a finished carton makes an awkward TI-HI.
Should pallet height be included in the loaded-height limit?
Yes. The maximum loaded height normally measures from the floor to the top of the load, so the empty pallet takes part of the allowance. Enter zero only when your stated limit already excludes the pallet height.
Does the calculator test rotated cartons?
Yes. For each rectangular layer grid, it tests the carton with its long side along the pallet length and with that footprint rotated. It does not mix orientations within a layer or test pinwheel and interlocking arrangements.
Can this result certify carton strength or pallet stability?
No. A full footprint and compliant payload do not establish compression strength, load stability, or safe handling. Confirm the final carton with representative samples, the pallet supplier, carrier, warehouse, and customer requirements.