Pallet Pattern Planner (Ti-Hi)
The same Ti×Hi count as the Pallet Configuration Calculator — plus a comparison of the real ways to stack it: column, interlocked (brick), and rotated 90°, each rated for stability, with the most stable one that doesn’t cost you cases recommended. See each as a top-down layer plan and a side elevation of the built stack — pick the pattern that fits how you ship.
Case / carton
Pallet
Total stack height including the pallet. Common caps: 48″, 60″, 72″. Set it to your dock, rack, or trailer limit.
Cap the stack by weight (a fragile product, a rack limit). Leave blank for a height-only stack.
Enter the whole order to also get the number of pallets it takes.
Recommended pattern — —
Compare patterns — pick one to view
Top view (the layer pattern)
Side view (the stack)
Why interlock the layers
Stack every layer the same way and you build columns: the cases line up top to bottom, and a column only has to lean a little to walk off the pallet — the failure warehouses call “telescoping.” Interlocking turns or offsets every other layer so a box on one layer bridges the seam between two boxes on the layer below, the way a brick wall staggers its joints. The load stops behaving like loose stacks and starts behaving like one block.
A column stack is strong straight down and weak in every other direction. Interlock trades a little vertical strength for a load that stays put.
Two ways to break the seam
When the case footprint lets both orientations fit the same number of boxes, the cleanest interlock is to turn every other layer 90° — the long sides cross, the strongest bond you can get without losing cases. When one orientation clearly packs more, the planner keeps that higher count and instead offsets alternate rows into the pallet’s spare space, so the vertical seams still stagger. Either way the cases-per-pallet number matches the honest single-orientation Ti×Hi — you never lose count to get the pattern.
When a clean interlock costs a case
Some cases tile one orientation so tightly there’s no room to stagger. When that happens the planner says so, and shows what a 90° turn would cost per layer, so the call between maximum count and maximum stability is yours to make — strapping, corner board, or a tie sheet can make up the difference on a tight column stack.