Master Carton Packing, EUR/US Pallet Ti-Hi Layer Layout & Courier Dimensional Weight Calculator
Master Carton Pallet Ti-Hi Layer Optimizer & Volumetric Weight Calculator
How This Master Carton & Pallet Ti-Hi Calculator Works
Shipping oversized cartons inflates freight bills in two ways: air and ground couriers (DHL, FedEx, UPS) bill by Volumetric Dimensional Weight (`W_DIM = L × W × H / 5000`) whenever DIM weight exceeds physical scale weight, and poorly proportioned master cartons leave wasted perimeter air on standard EUR EPAL (`1200 × 800 mm`) or US GMA (`1219 × 1016 mm` / `48 × 40 in`) pallets. Our Master Carton & Pallet Ti-Hi Calculator optimizes 0° and 90° carton footprints per pallet layer (Ti), vertical stacking tiers (Hi), total pallet gross weight, and courier billable weight.
Governing Mathematical Equations (ISO 6780 Standard Flat Pallets (EUR 1200×800 / US GMA 48×40") & IATA Volumetric Weight)
Evaluates both lengthwise and rotated pallet layer arrangements to maximize cartons per tier (Ti) multiplied by vertical tiers (Hi).
Computes chargeable air/express parcel weight using international IATA/courier DIM divisors.
Measures how tightly the master carton footprint fills the pallet deck without overhang.
Global ISO 6780 Pallet Standards & Courier Dimensional Weight Divisors
| Standard / Carrier | Dimensions (Metric) | Dimensions (Imperial) | Max Deck Height / Rule | Primary Region |
|---|---|---|---|---|
| US GMA Standard Pallet | 1219 × 1016 mm | 48.0 × 40.0 in | Max 1500 – 1800 mm height | North America retail & LTL freight |
| EUR / EPAL 1 Euro Pallet | 1200 × 800 mm | 47.2 × 31.5 in | Max 1400 – 1650 mm height | European Union logistics & rail |
| UK / Industrial ISO Pallet | 1200 × 1000 mm | 47.2 × 39.4 in | Max 1600 – 1800 mm height | UK, Asia-Pacific & sea containers |
| DHL / FedEx / UPS Express | DIM Divisor: 5000 (cm³/kg) | DIM Divisor: 139 (in³/lb) | Billed at max(Actual, DIM) | Global air & express parcel |
Apply These Calculations in 1:1 Parametric CAD Studios
FEFCO 0427 E-Commerce Mailer Box Dieline Generator
FEFCO 0201 Regular Slotted Container (RSC) Corrugated Shipping Box Dieline Generator
Rigid Book Mailer & Variable-Capacity Envelope Folder Dieline Generator (With Tear Strip)
Frequently Asked Questions — Master Carton & Pallet Ti-Hi
What does Ti-Hi mean in palletizing and warehouse logistics?
Ti (Tier) is the number of master cartons arranged on a single horizontal layer on the pallet deck, and Hi (Height) is the number of vertical layers stacked high. A pallet with 10 boxes per layer stacked 5 layers tall has a Ti-Hi of 10 × 5 = 50 cartons.
Why should master cartons never overhang the edge of a pallet?
Allowing corrugated boxes to overhang a pallet edge by even 15mm–25mm destroys up to 30%–40% of their vertical compression strength (BCT), because the box corners no longer rest squarely on the wooden pallet deckboards.
How can I reduce courier Dimensional Weight charges?
Reducing carton height (H) by just 20mm–30mm—or switching to a multi-depth scored FEFCO 0201 RSC or compact FEFCO 0401 book mailer—directly shrinks cubic volume and can drop your parcel into a lower billable weight bracket.