A utilization percentage needs a named numerator and denominator
Different cube percentages can be correct for the same load because they compare the same case volume with different rectangular reference volumes. Before investigating a discrepancy, identify which numerator and denominator the output uses. Product-stack space excludes the base, planned loaded envelope includes it, and maximum-reference envelope can also include unused headroom. A percentage without those labels is difficult to reproduce and can suggest a fuller load than the intended comparison supports.
The cube calculator uses the outside rectangular volume of each case, not product net volume or the material volume of the carton. It assumes identical cases and the returned complete-layer layout in build mode. Those external case boxes can contain voids internally. An envelope percentage therefore describes geometric occupation under the entered model, not the fraction of actual solid goods, billed capacity or a structural efficiency measure.
Build one numerator and three reference volumes
Assume a 1200 by 800 mm deck, a 144 mm base and cases 400 by 300 by 250 mm. Rotation is disabled and the stated zero-spacing uniform pattern has six cases per layer. A maximum total height of 1500 mm allows five complete layers, giving thirty cases. Each outside case box has volume 400 times 300 times 250 = 30000000 cubic millimeters, or 0.03 cubic meters. Total external case volume is 0.9 cubic meters.
The cargo height is five times 250 = 1250 mm. Product-stack reference volume is 1200 times 800 times 1250, or 1.2 cubic meters. Planned loaded height is 144 + 1250 = 1394 mm, giving a planned outside envelope of 1.33824 cubic meters. The maximum-reference envelope uses the entered 1500 mm condition, giving 1.44 cubic meters. The three denominators describe different boundaries around the same stated case group.
| Output comparison | Denominator | Computed fraction |
|---|---|---|
| Geometric cube fill | 1.2 m³ product-stack envelope | 0.9 / 1.2 = 75% |
| Planned envelope fill | 1.33824 m³ base-plus-cargo envelope | Approximately 67.25% |
| Maximum-reference fill | 1.44 m³ envelope to the entered height limit | 0.9 / 1.44 = 62.5% |
| Case-volume numerator | 30 × 0.03 m³ | 0.9 m³ in all three ratios |
| Unused headroom | 1500 − 1394 | 106 mm, not another occupied layer |
Explain the lower percentages without changing the load
The planned-envelope percentage is lower than geometric cube fill because its denominator includes the 144 mm base height while the numerator still contains only cases. The maximum-reference percentage is lower again because it includes the 106 mm of unused height above the planned load. Neither change means cases were removed between the calculations. The same thirty-case numerator is divided by a progressively larger reference envelope.
The footprint fraction in this example is six times 400 times 300 divided by 1200 times 800, or 75 percent. It matches product-stack geometric fill because identical complete layers repeat the same footprint and height. That equality is specific to this model. A finished irregular load, different-height top cases or a widened wrapped envelope needs an appropriate observed record rather than an assumed repetition of the same ratio.
Compare the height mode before comparing percentages
In maximum-height build mode, the reference can retain the entered limit above the complete occupied layers. In a fixed-layer build mode, the reference height follows the planned loaded height, so the planned and reference envelope volumes can coincide. A change from 62.5 to approximately 67.25 percent may therefore be a denominator-mode change rather than an improvement in case arrangement. Preserve the selected height mode with the result.
The known loaded-dimensions mode calculates the supplied outside rectangular envelope directly. It does not reconstruct case count, TI, HI or external case volume from a length, width and height alone. Without a case numerator and a suitable reference, the utilization ratios are not determined. Do not fill an absent percentage with zero or infer that a known measured envelope is completely filled with solid cargo.
Make a cube-denominator audit record
Write mode, TI, HI, outside case dimensions, case count, pallet dimensions, base height, planned loaded height and the maximum-height condition if used. Save external case volume, product-stack envelope, planned envelope and reference envelope with their labels. For the example retain 0.9, 1.2, 1.33824 and 1.44 m³, then 75%, approximately 67.25% and 62.5%.
Inspect the actual result fields and their scope
Use the pallet cube calculator in build mode with the stated case dimensions, deck, base, no rotation and 1500 mm maximum total height. Compare the three percentage labels and their volumes rather than choosing the largest percentage for a report. Review the layout status too: a finite search’s best-found pattern is a discovered candidate, and any resulting volume calculation inherits that case-count scenario.
For a directly measured finished unit, switch to known loaded dimensions and enter the outside envelope appropriate to that task. The measurement may include wrap, straps or projections beyond the deck and tallest case. Keep it separate from the nominal build envelope if they differ. This calculator’s rectangular cube is not a shape scan, a sum of solid materials or confirmation of a carrier’s billing denominator.
Write the percentage as a comparison, not an unexplained score
A useful report states “external case volume divided by product-stack envelope” or the corresponding planned or maximum reference. Include the volumes so a recipient can reproduce the fraction. If two reports disagree, first check numerator, height mode and base inclusion, then compare the actual layout and case dimensions. A consistent cube ratio does not establish load capacity, handling clearance or transport approval. Those requirements need their own documented checks.
Reference scope
EPAL 1 product information supports the named deck and base reference used in the denominator example. The case dimensions and height condition are stated assumptions rather than measured cargo evidence.