A pallet pattern is the answer to two questions asked together: how do the cases sit on one layer, and how do the layers sit on each other. It is normally written as Ti-Hi, where Ti is the number of cases in a tier and Hi is the number of tiers. A 12 by 5 pattern means twelve cases per layer, five layers, sixty cases on the pallet.
The deck you are designing to
Most North American freight moves on a 48 x 40 in pallet. Much of Europe uses a 1200 x 800 mm pallet. If your product ships to both, the same case size will rarely tile both decks well, and that is worth knowing before you commit a die rather than after.
The useful arithmetic is simple. 48 divides evenly by 4, 6, 8, 12, 16 and 24. 40 divides evenly by 4, 5, 8, 10 and 20. Pair one from each list and the layer fills completely.
| Case footprint | Cases per layer (Ti) | Deck used |
|---|---|---|
| 24 x 20 in | 4 | Full |
| 16 x 20 in | 6 | Full |
| 12 x 20 in | 8 | Full |
| 16 x 10 in | 12 | Full |
| 12 x 10 in | 16 | Full |
| 8 x 10 in | 24 | Full |
Column stack or interlock
These are the two families of pattern and they trade against each other.
Column stacking puts every case directly above the one below, corner on corner. Because a corrugated case carries most of its compression load through the four vertical corners, this is the stronger arrangement for the same board. Its weakness is that the layers are not tied together, so the load relies on wrap, strapping or a slip sheet to stop it shearing.
Interlocking rotates alternate layers so cases bridge the joints below. That ties the load together and resists shifting in transit, but it puts case corners over panel centres, which is the weakest place to land a load. For the same board you get a more stable pallet and a lower stack strength.
The usual resolution is column stack with good wrapping if the load is heavy and stacked, interlock if the load is light and the handling is rough. Your freight partner will have a view worth asking for.
Overhang and underhang
Overhang is a case hanging past the deck edge. It is expensive because the unsupported part is exactly the corner that carries the load, so the whole stack loses capacity. Underhang wastes cube: you are paying to ship air and the load is more likely to shift. Aim for a pattern that reaches the deck edges without passing them.
Height, weight and the trailer
The pattern is not finished at the layer. Stack height is limited by the trailer or container door, by what a forklift can handle safely, and by what the bottom layer of cases can carry. A 53 ft trailer is commonly loaded with 26 standard pallet positions in a single stack arrangement, though the exact number depends on how the pallets are turned and what your carrier allows, so confirm it rather than assuming it.
Designing the case to the pattern
The practical takeaway is that the pallet should influence the box, not the reverse. Changing a case footprint by an inch can add a whole case to every layer, and that saving repeats on every pallet you ever ship. If you are choosing a footprint now, the divisor approach is worked through on what size stackable storage box do I need, and board grade for tall stacks is covered on single wall vs double wall corrugated.
Orders start at 100 boxes, from about $0.48 per unit at bulk volumes, confirmed on your written quote, with the die, the plates, design support, US shipping and a digital proof included. Turnaround is stated per product across three lanes, rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days of production plus 2 to 5 days for delivery. Send your case size and the pallet you ship on at request a quote and we will check the pattern before the die is cut.
