The process of stacking products onto a pallet according to a specified pattern.
Detailed Definition
A pallet build is both the act of stacking cases onto a pallet and the resulting load. A specified build normally sets the stacking pattern, cases per layer and number of layers (often written as TI x HI), label orientation, overall height and weight limits, and how the load is secured with stretch wrap, corner boards or banding. Builds may be done by hand or by a palletizer. A good build keeps cases within the pallet edges so the unit load stays stable in transit and storage.
Patterns and TI x HI
TI is the number of cases in one layer and HI is the number of layers, so a 10 x 5 build holds 50 cases. Column stacking puts each case directly over the one below and makes the most of box compression strength, but columns can lean apart. Interlocked or brick patterns rotate alternate layers to tie the load together, at the cost of some stacking strength because box corners no longer line up. The right choice depends on the box, the product and the trip.
Overhang and underhang
Cases that extend past the pallet edge lose support from the deck, are easily crushed and lose much of their stacking strength. Underhang, where the load sits well inside the edges, wastes space and can leave outer deck boards unloaded. Most builds aim for cases flush with the edges of the 48x40 pallet or whatever footprint the customer requires.
Checks before the load ships
- Height and weight match the customer's routing guide and the trailer plan.
- Labels face outward on the sides the receiver expects.
- Stretch wrap is anchored to the pallet itself, not only to the cases.
- The pallet is sound, with no broken top boards under heavy cases.
Related Glossary Terms
Frequently Asked Questions
What does TI x HI mean on a pallet build?
TI x HI describes how cases are stacked. TI, sometimes spelled tie, is the number of cases per layer, and HI is the number of layers. Multiply them for cases per pallet, so a 12 x 6 build holds 72 cases. Suppliers and retailers record the TI x HI for each item so warehouses build consistent pallets and can plan storage space and trailer loads.
Should a pallet build be column stacked or interlocked?
Column stacking keeps box corners aligned, which gives the highest box compression strength and suits heavy or tall stacks of sturdy cases. Interlocking ties layers together so the load resists shifting, but it lowers stacking strength because box corners rest on the weaker panels of the boxes below. Many shippers combine column stacking with good stretch wrap, corner boards or tier sheets. Test the build if the product is fragile or travels far.