Pallet Configuration Guide by Product Type: Tape, Fabric, Textiles & More

Pallet configuration varies significantly by product type — not just carton size. Tape rolls, fabric bolts, agricultural fabric, and textiles all have specific stacking, weight, and stability considerations that affect Ti Hi. This guide covers the most common product categories and the pallet configurations that work best for each.

Pallet Configuration for Tape

Tape — masking tape, duct tape, HVAC tape, industrial rolls — is one of the densest products to palletize. Individual rolls are light, but full cartons of tape can be surprisingly heavy, making weight the binding constraint rather than height.

Boxed tape rolls (standard 3" core): A typical 12×12×10-inch tape carton fits Ti 16 on a 48×40 pallet (4 across × 4 deep). At a carton weight of 15–25 lbs, Hi is weight-limited: at 20 lbs/carton, 5 layers = 100 cartons × 20 lbs = 2,000 lbs — exactly at the carrier limit. Most tape shippers run Ti 16, Hi 4 (64 cartons, ~1,280 lbs) to stay comfortably under the limit.

Large format tape rolls (floor marking, packaging): Bigger cores and wider rolls increase carton dimensions significantly. Calculate Ti Hi using the free pallet calculator with your specific carton size — orientation matters because tape carton footprints are often square, giving the same Ti in both orientations.

Pallet configuration for tape — key rules:

• Always calculate total pallet weight before finalising Hi — tape is deceptively dense
• Interleave layers with slip sheets or tier sheets to prevent carton compression damage on the bottom layers
• Stretch wrap tightly — individual rolls can shift inside cartons, making pallets unstable in transit

Pallet Configuration for Fabric

Fabric ships in two primary forms: folded in cartons, and rolled on cores (bolts). Each requires a completely different pallet configuration approach.

Folded fabric in cartons

Treat exactly like standard carton palletization — use Ti Hi calculated from carton dimensions. Fabric cartons are typically light (10–20 lbs), so height is the binding constraint. A 20×16×12-inch fabric carton on a 48×40 pallet gives Ti 6 (2×3), Hi 4 at 54-inch max height = 24 cartons per pallet. Use the pallet calculator with your exact carton dimensions.

Rolled fabric (bolts on cores)

Fabric bolts cannot be stacked on top of each other without damage. The standard approach is a single-layer configuration with bolts standing upright:

Secure with edge protectors on all four corners and heavy-gauge stretch wrap. Do not band horizontally across the cores — banding distorts the roll edges and causes waste when cutting.

Pallet Configuration for Textiles and Apparel

Textiles and apparel are ideal for high-Ti-Hi palletization because cartons are light and consistently sized. Most apparel operations target a Ti 9, Hi 5 or Ti 9, Hi 6 configuration on 48×40 pallets, hitting 45–54 cartons per pallet at well under the weight limit.

Common apparel carton example: 16×12×10-inch carton, 8 lbs. Ti = floor(48÷16)×floor(40÷12) = 3×3 = 9. At 60-inch max pallet height minus 5.5-inch board = 54.5 inches usable. Hi = floor(54.5÷10) = 5 layers. Total: 45 cartons, 360 lbs — weight is nowhere near the limit, height is the constraint.

Retail compliance for textiles: Major retailers require consistent Ti Hi per SKU. Once you establish Ti 9, Hi 5 for an apparel SKU, every pallet of that item must match. Mixed-height pallets are rejected at most retail DCs. Confirm your Ti Hi against the retailer's vendor compliance guide before the first shipment.

Pallet Configuration for Agricultural Fabric

Agricultural fabric (row cover, weed barrier, landscape fabric, silage wrap) ships almost exclusively on large rolls — rarely in cartons. Roll configurations depend on roll diameter and the fabric's weight per linear metre.

Standard ag fabric roll configuration:

• Light row cover (1.0–1.5 oz/sq yd): Rolls are large diameter but very light. Stand upright, 4–6 rolls per pallet depending on diameter. Pallet weight is rarely a constraint — stability is. Use a pallet base board between roll and pallet deck to prevent core indentation.
• Weed barrier / landscape fabric (3–5 oz/sq yd): Heavier rolls — calculate total pallet weight carefully. A 300m roll of 6-foot wide 3-oz landscape fabric weighs approximately 35–45 lbs. 6 rolls = 210–270 lbs — well under the limit but verify for your specific product.
• Silage wrap / stretch film: Dense, heavy rolls. Single layer, 4 rolls per pallet maximum, standing upright. Total pallet weight can reach 1,500–2,000 lbs depending on roll size. Always check before stacking.

General Pallet Configuration Rules for All Product Types