TDL2 Warehouse Packing&Loading
TDL2 Warehouse Packing&Loading
TDL2 Warehouse Packing&Loading
Core Topics: Using formulas, converting measurements, performing operations with decimals and
percents, solving multi-step word problems
Objective: Students will be able to calculate area and volume, convert inches and feet, and compute
percentages in order to accurately solve problems involving packing pallets and loading trucks.
Materials included:
Instructor’s notes
Scenario: Warehouse Packing & Loading
Student worksheets
Quiz
Answer Keys
Industry Overview:
According to the U.S. Department of Labor, employment in the transportation and material movers
industry is expected to grow approximately 8.6% between 2012 and 2022.* The transportation,
distribution, and logistics (TDL) industry is comprised of a vast array of jobs, ranging from dock
workers and delivery drivers to warehouse managers and logisticians. Mathematics and literacy skills
are essential for students who plan to pursue a career in this field. TDL employees, including
warehouse and distribution workers, must have the ability to use formulas and perform accurate
mathematical calculations in their daily work.
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Instructor’s notes:
The purpose of this module is to help students develop and apply math skills in a TDL
workplace setting. The learning activities were designed to be incorporated throughout
multiple instructional periods as math concepts are taught in a TDL context.
Setting the stage: Provide students with background information about the typical
responsibilities of warehouse and distribution center employees. You may want to have
students use the occupational outlook handbook, O*NET and/or other relevant websites to
research the job responsibilities, educational/training requirements, salary, etc. for TDL
positions that interest them. In addition, you could have students view videos depicting typical
warehouse and distribution center operations. (See links below)
For Activity 1: Explain the formula to find the area of a rectangle. Work the scenario
example problems with the class. Have students work the practice problems independently.
Provide additional practice as needed. Have students complete Worksheet 1.
For Activity 2: Explain the steps to solving multi-step weight problems. Work the scenario
example problems with the class. Have students complete the practice problems
independently. Provide additional practice as needed. Have students complete Worksheet 2.
For Activity 3: Explain and review converting inches into feet and using the formula to find
the volume of a rectangular prism. Work the scenario example problems with the class. Have
students complete the practice problems independently. Provide additional practice as
needed. Have students complete Worksheet 3.
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Workplace Scenario:
You are a supervisor at BSP Warehouse & Distribution, Inc. Your company provides storage and
shipping services for several vendors throughout the Midwest. One of your primary responsibilities is
to train and supervise warehouse employees. This week you are training Julie, a new employee, on
the packing and loading procedures for outbound shipments. You tell Julie that when customer orders
are received, warehouse pickers use forklifts, hand trucks, and wheeled bins to retrieve the products
from warehouse racks. The products are then brought to the packing zone of the warehouse to be
scanned and packed on pallets. Cases are stacked on pallets in a variety of patterns, depending on
the size and weight of the cartons and other product requirements.
12” L x 8.5” W x 14” H → A=LxW → 12 x 8.5 = 102 square inches or 102 in2
14” L x 6” W x 15” H
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Activity 1: Packing Pallets – Calculating Area Continued
Example 2: You receive a packing order for 120 cases of item #101. The dimensions of one case
are 14” L x 13” W x 12” H. The maximum stacking height for this product is 4 cases.
a. What is the total number of cases you can fit on one layer of a 48” x 40” pallet?
Calculate the area of the pallet: 48 x 40 = 1920 square inches.
Calculate the area of one case: 14 x 13 = 182 square inches.
Divide the area of the pallet by the area of the case: 1920 ÷ 182 = 10.5; thus, 10 cases will fit
on one layer of the pallet. (Note: you will always round down, if necessary).
b. If you put 10 cases on the first layer of the pallet, and you stack the cases 4 high, how many
cases will you pack on one pallet?
Multiply the number of cases in one layer by the number of layers: 10 x 4 = 40 cases. .
Practice 2: You receive a packing order for 280 cases of item #102. The case dimensions for this
item are 13” L x 10.5” W x 15” H. The maximum pallet height for the truck delivering this order is 6.5
feet.
a. What is the total number of cases you can fit on one layer of a 48” x 40” pallet?
Calculate the area of the pallet:
Calculate the area of one case:
Divide the area of the pallet by the area of the case:
b. How many cases high can you stack this order on a pallet?
Convert the maximum pallet height of 6.5 feet into inches by multiplying by 12:
Divide the result by 15 inches, the height of one case:
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Worksheet 1: Packing Pallets – Calculating Area Name _______________________
You received the following packing orders. Make all the required calculations to pack the
pallets for these orders.
1. You receive a packing order for 400 cases of item #103. The case dimensions for this item are
12” L x 15” W x 10” H. The maximum case stacking height for this product is 8 cases.
a. What is the total number of cases you can fit on one layer of a 48” x 40” pallet?
b. If you stack the cases 8 high, how many total cases can you load on one pallet?
c. How many pallets will you need for this order?
2. You receive a packing order for 240 cases of item #104. The case dimensions for this item are
24” L x 20” W x 20” H. The maximum pallet height for the truck delivering this order is 7 feet.
a. What is the total number of cases you can fit on one layer of a 48” x 40” pallet?
b. How many cases high can you stack this order on a pallet?
c. How many total cases will you stack on one pallet?
d. How many pallets will you need for this order?
3. You receive a packing order for 480 cases of item #105. The case dimensions for this item are
15” L x 10.5” W x 8” H. The maximum pallet height for the truck delivering this order is 7 feet.
a. What is the total number of cases you can fit on one layer of a 36” x 36” pallet?
b. How many cases high can you stack this order on a pallet?
c. How many total cases will you stack on one pallet?
d. How many pallets will you need for this order?
4. You receive a packing order for 360 cases of item #106. The case dimensions for this item are
18.5” L x 12.5” W x 15” H. The maximum case stacking height for this product is 5 cases.
a. What is the total number of cases you can fit on one layer of a 48” x 40” pallet?
b. How many total cases will you stack on one pallet?
c. How many pallets will you need for this order?
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Activity 2: Packing Pallets – Calculating Weight
Weight is another important factor which must be considered when loading pallets. Both pallets and
delivery trucks have maximum weight limits which must be followed.
When you receive a packing order, you will check the case weight of the product, the pallet weight,
and the maximum loaded pallet weight allowed for the order. You will use this information to
calculate the total weight for each loaded pallet and verify that the weight of the load is safe.
Example 1: You receive a packing order for 120 cases of item #201. You pack 40 cases each on 3
pallets. Each case weighs 35.2 lbs. and each empty pallet weighs 45 lbs. The maximum loaded
pallet weight for this order is 1500 lbs.
Multiply the weight of one case by the total number of cases loaded on one pallet. Add the
result to the weight of the empty pallet.
Compare the loaded pallet weight you calculated to the maximum weight allowed.
Yes, 1453 lbs. is less than the 1500 lb. maximum allowed.
Multiply the weight of one loaded pallet by the total number of pallets.
Practice 1: You receive a packing order for 280 cases of item #202. You pack 70 cases each on 4
pallets. Each case weighs 26.5 lbs. and each pallet weighs 45 lbs. The maximum loaded pallet
weight for this order is 2000 lbs.
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Worksheet 2: Packing Pallets – Calculating Weight Name _______________________
Perform the weight calculations for each of the following packing orders.
1. You receive a packing order for 400 cases of item #203. You pack 80 cases each on 5 pallets.
Each case weighs 24 lbs. and each pallet weighs 45 lbs. The maximum loaded pallet weight
for this order is 2000 lbs.
2. You receive a packing order for 240 cases of item #204. You pack 16 cases each on 15
pallets. Each case weighs 43.5 lbs. and each pallet weighs 45 lbs. The maximum loaded
pallet weight for this order is 1500 lbs.
3. You receive a packing order for 480 cases of item #205. You pack 80 cases each on 6 pallets.
Each case weighs 25 lbs. and each pallet weighs 45 lbs. The maximum loaded pallet weight
for this order is 2000 lbs.
4. You receive a packing order for 360 cases of item #206. You pack 40 cases each on 9 pallets.
Each case weighs 36.3 lbs. and each pallet weighs 45 lbs. The maximum loaded pallet weight
for this order is 1500 lbs.
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Activity 3: Loading Trucks – Volume and Weight
You explain to Julie that she will need to calculate the volume and weight of each loaded pallet to
ensure that outgoing shipments will fit in the designated delivery truck. Your company uses different
size delivery trucks, depending on the volume and weight of the orders.
The formula to find the volume of a rectangular prism: Volume = Length x Width x Height
Note: Volume is always written in cubic units.
You will need to convert inches into feet before calculating the volume of a loaded pallet. To convert
inches into feet, divide by 12. Round your answers to the nearest tenths place, if necessary.
Example: Your order has 6 loaded pallets, each measuring 48” L x 40” W x 60” H. Find the volume
of one loaded pallet and the entire order.
Step 2: Calculate the volume in cubic feet of one pallet. V = L x W x H → 4 x 3.3 x 5 = 66 ft3
Step 3: Multiply by the number of pallets to find the volume for the entire order. 66 x 6 = 396 ft3
Practice 1a: Your order has 12 full pallets and each pallet contains 50 cases. Each case weighs
38.2 lbs. and each empty pallet weighs 45 lbs. The dimensions for each loaded pallet are 48” L x 40”
W x 84” H. Find the volume and weight of one loaded pallet and the entire order.
Step 3: Multiply by the number of pallets to find the volume of the entire order.
Step 5: Multiply by the number of pallets to find the weight of the entire order.
Practice 1b: A 36 foot delivery truck has the following interior load dimensions, 35’ L x 7.5’ W x 7’ H.
The truck holds a maximum of 16 standard 48” x 40” pallets and has a maximum weight capacity of
30,000 lbs. Calculate the volume of the truck.
You use this truck for the order in 1a above. What percent of the truck’s weight capacity would the
order require? To find the percent, divide the weight of the order by the weight capacity of the truck.
What percent of the truck’s volume capacity would the order require? To find the percent, divide the
total volume of the order by the total weight capacity of the truck.
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Worksheet 3: Loading Trucks – Volume and Weight Name __________________
1. Your company has the following trucks available for outgoing shipments. Calculate the
total volume for each truck.
a. Truck A: 28 foot truck will hold a maximum of 12 standard pallets. It has a weight limit of
20,000 lbs. The interior load dimensions for this truck are 27’ L x 7’ W x 6.5 H.
b. Truck B: 42 foot truck will hold a maximum of 20 standard pallets. It has a weight limit of
38,000 lbs. The interior load dimensions for this truck are 41’ L x 7’ W x 7.5’ H.
c. Truck C: 53 foot tractor trailer will hold a maximum of 26 standard pallets It has a weight limit
of 45,000 lbs. The load dimensions for this truck are 52’ L x 7.5’ W x 8’ H.
2. Find the volume and weight of one loaded pallet and the entire order for each of the
following.
a. An order has 12 full pallets and each pallet contains 40 cases. Each case weighs 35.5 lbs.
and each empty pallet weighs 45 lbs. The dimensions for each loaded pallet are 48” L x 40” W
x 66” H
b. An order has 20 full pallets and each pallet contains 36 cases. Each case weighs 47.3 lbs.
and each empty pallet weighs 45 lbs. The dimensions for each loaded pallet are 48” L x 40” W
x 78” H.
c. An order has 24 full pallets and each pallet contains 100 cases. Each case weighs 18.2 lbs.
and each empty pallet weighs 45 lbs. The dimensions for each loaded pallet are 48” L x 40” W
x 84” H
a. You load truck A with the order in #2a above. What percent of the truck’s weight capacity
would the order require? What percent of the truck’s volume capacity would the order require?
b. You load truck B with the order in #2b above. What percent of the truck’s weight capacity
would the order require? What percent of the truck’s volume capacity would the order require?
c. You load truck C with the order in #2c above. What percent of the truck’s weight capacity
would the order require? What percent of the truck’s volume capacity would the order require?
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Quiz: Packing and Loading Calculations Name: _________________
1. You receive a packing order for 600 cases of item #401. The case dimensions for this item are
20” L x 15” W x 8” H. The maximum pallet height for the truck delivering this order is 7 feet.
a. What is the total number of cases you can fit on one layer of a 48” x 40” pallet?
b. How many cases high can you stack this order on a pallet?
2. You receive a packing order for 500 cases of item #402. You pack 100 cases each on 5
pallets. Each case weighs 16.5 lbs. and each pallet weighs 45 lbs. The maximum loaded
pallet weight for this order is 2000 lbs.
3. A 45 foot truck will hold a maximum of 22 standard pallets. It has a weight limit of 40,000 lbs.
The interior load dimensions for this truck are 44’ L x 7’ W x 7.5’ H.
4. Your order has 20 full pallets and each pallet contains 60 cases. Each case weighs 31.5 lbs.
and each empty pallet weighs 45 lbs. The dimensions for each loaded pallet are 48” L x 40” W
x 85” H.
5. You load the truck from #3 with the order from #4 above.
a. What percent of the truck’s weight capacity would the order require?
b. What percent of the truck’s volume capacity would the order require?
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Practice Problems Answer Key
Activity 1
Practice 1: 14 x 6 = 84 in2
20 x 13.5 = 270 in2
15.5 x 14 = 217 in2
Practice 2a: 48 x 40 = 1920 in2
13 x 10.5 = 136.5 in2
1920 ÷ 136.5 = 14.1, round down → 14 cases per layer
Practice 2b: 6.5 x 12 = 78 inches
78 ÷ 15 = 5.2, round down → 5 cases high
Practice 2c: 14 x 5 = 70 cases per pallet
Practice 2d: 280 ÷ 70 = 4 pallets needed for the order
Activity 2
Practice 1a: 70 x 26.5 + 45 = 1900 lbs. per pallet
Practice 1b: Yes; 1900 is less than the 2000 lb. maximum
Practice 1c: 1900 x 4 = 7600 lbs. for the total order
Activity 3
Practice 1a: Convert inches to feet: 48 ÷ 12 = 4’ 40 ÷ 12 = 3.3’ 84 ÷ 12 = 7’
Volume of one pallet: 4 x 3.3 x 7 = 92.4 ft3
Volume of entire order: 92.4 x 12 = 1108 ft3
Weight of one pallet: 50 x 38.2 + 45 = 1955 lbs.
Weight of the entire order: 1955 x 12 = 23,460 lbs.
Practice 1b: Volume of the truck: 35 x 7.5 x 7 = 1837.5 ft3
23,460 ÷ 30,000 = .782 → 78.2%
1108 ÷ 1837.5 = .603 → 60.3%
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Worksheet 1: Packing Pallets – Calculating Area Answer Key
1. You receive a packing order for 400 cases of item #103. The case dimensions for this item are
12” L x 15” W x 10” H. The maximum case stacking height for this product is 8 cases.
a. What is the total number of cases you can fit on one layer of a 48” x 40” pallet?
48 x 40 = 1920 sq. in.; 12 x 15 = 180 sq. in.; 1920 ÷ 180 = 10.6 → 10 cases per layer
b. If you stack the cases 8 high, how many total cases can you load on one pallet?
10 x 8 = 80 cases per pallet
c. How many pallets will you need for this order? 400 ÷ 80 = 5 pallets
2. You receive a packing order for 240 cases of item #104. The case dimensions for this item are
24” L x 20” W x 20” H. The maximum pallet height for the truck delivering this order is 7 feet.
a. What is the total number of cases you can fit on one layer of a 48” x 40” pallet?
48 x 40 = 1920; 24 x 20 = 480; 1920 ÷ 480 = 4 cases per layer
b. How many cases high can you stack this order on a pallet? Max. truck height: 7 feet;
7 x 12 = 84 in.; case height: 20 in.; 84 ÷ 20 = 4.2 → 4 cases high
7 How many total cases will you stack on one pallet? 4 x 4 = 16 cases per pallet
8 How many pallets will you need for this order? 240 ÷ 16 = 15 pallets
3. You receive a packing order for 480 cases of item #105. The case dimensions for this item are
15” L x 10.5” W x 8” H. The maximum pallet height for the truck delivering this order is 7 feet.
a. What is the total number of cases you can fit on one layer of a 36” x 36” pallet?
36 x 36 = 1296 sq. in.; 15 x 10.5 = 157.5 sq. in.; 1296 ÷ 157.5 = 8.2 → 8 cases per layer
b. How many cases high can you stack this order on a pallet? Max. truck height: 7 feet;
7 x 12 = 84 in.; case height: 8 in.; 84 ÷ 8 = 10.5 → 10 cases high
c. How many total cases will you stack on one pallet? 8 x 10 = 80 cases per pallet
d. How many pallets will you need for this order? 480 ÷ 80 = 6 pallets
4. You receive a packing order for 360 cases of item #106. The case dimensions for this item are
18.5” L x 12.5” W x 15” H. The maximum case stacking height for this product is 5 cases.
a. What is the total number of cases you can fit on one layer of a 48” x 40” pallet?
48 x 40 = 1920 sq. in.; 18.5 x 12.5 = 231.25 sq. in.; 1920 ÷ 231.25 = 8.3 → 8 cases per layer
b. How many total cases will you stack on one pallet? 8 x 5 = 40 cases per pallet
c. How many pallets will you need for this order? 360 ÷ 40 = 9 pallets
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Worksheet 2: Packing Pallets – Calculating Weight Answer Key
1. You receive a packing order for 400 cases of item #203. You pack 80 cases each on 5 pallets.
Each case weighs 24 lbs. and each pallet weighs 45 lbs. The maximum loaded pallet weight
for this order is 2000 lbs.
a. What is the weight of one loaded pallet? 80 x 24 = 1920; 1920 + 45 = 1965 lbs.
b. Is the weight of the load safe? Yes, 1965 is less than the 2000 lb. maximum allowed.
c. What is the total load weight for the entire order? 1965 x 5 = 9825 lbs.
2. You receive a packing order for 240 cases of item #204. You pack 16 cases each on 15
pallets. Each case weighs 43.5 lbs. and each pallet weighs 45 lbs. The maximum loaded
pallet weight for this order is 1500 lbs.
a. What is the weight of one loaded pallet? 16 x 43.5 = 696; 696 + 45 = 741 lbs.
b. Is the weight of the load safe? Yes, 741 is less than the 1500 lb. maximum allowed.
c. What is the total load weight for the entire order? 741 x 15 = 11,115 lbs.
3. You receive a packing order for 480 cases of item #205. You pack 80 cases each on 6 pallets.
Each case weighs 25 lbs. and each pallet weighs 45 lbs. The maximum loaded pallet weight
for this order is 2000 lbs.
a. What is the weight of one loaded pallet? 80 x 25 = 2000; 2000 + 45 = 2045 lbs.
b. Is the weight of the load safe? No, 2045 is more than the 2000 lb. maximum allowed.
c. What is the total load weight for the entire order? 2045 x 6 = 12,270 lbs.
4. You receive a packing order for 360 cases of item #206. You pack 40 cases each on 9 pallets.
Each case weighs 36.3 lbs. and each pallet weighs 45 lbs. The maximum loaded pallet weight
for this order is 1500 lbs.
a. What is the weight of one loaded pallet? 40 x 36.3 = 1452; 1452 + 45 = 1497 lbs.
b. Is the weight of the load safe? Yes, 1497 is less than the 1500 maximum allowed.
c. What is the total load weight for the entire order? 1497 x 9 = 13,473 lbs.
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Worksheet 3: Loading Trucks – Volume and Weight Answer Key
1. Your company has the following trucks available for outgoing shipments. Calculate the
total volume for each truck.
a. Truck A: 28 foot truck will hold a maximum of 12 standard pallets. It has a weight limit of
20,000 lbs. The interior load dimensions for this truck are 27’ L x 7’ W x 6.5 H.
27 x 7 x 6.5 = 1228.5 cubic feet
b. Truck B: 42 foot truck will hold a maximum of 20 standard pallets. It has a weight limit of
38,000 lbs. The interior load dimensions for this truck are 41’ L x 7’ W x 7.5’ H.
41 x 7 x 7.5 = 2152.5 cubic feet
c. Truck C: 53 foot tractor trailer will hold a maximum of 26 standard pallets It has a weight limit
of 45,000 lbs. The load dimensions for this truck are 52’ L x 7.5’ W x 8’ H.
52 x 7.5 x 8 = 3120 cubic feet
2. Find the volume and weight of one loaded pallet and the entire order for each of the
following.
a. An order has 12 full pallets and each pallet contains 40 cases. Each case weighs 35.5 lbs.
and each empty pallet weighs 45 lbs. The dimensions for each loaded pallet are 48” L x 40” W
x 66” H. 4 x 3.3 x 5.5 = 72.6 cu. ft. per pallet 72.6 x 12 = 871.2 cu. ft. per order
35.5 x 40 = 1420 + 45 = 1465 lbs. per pallet 1465 x 12 = 17580 lbs. per order
b. An order has 20 full pallets and each pallet contains 36 cases. Each case weighs 47.3 lbs.
and each empty pallet weighs 45 lbs. The dimensions for each loaded pallet are 48” L x 40” W
x 78” H. 4 x 3.3 x 6.5 = 85.8 cu. ft. per pallet 85.8 x 20 = 1716 cu. ft. per order
47.3 x 36 = 1702.8 + 45 = 1747.8 lbs. per pallet 1747.8 x 20 = 34,956 lbs. per order
c. An order has 24 full pallets and each pallet contains 100 cases. Each case weighs 18.2 lbs.
and each empty pallet weighs 45 lbs. The dimensions for each loaded pallet are 48” L x 40” W
x 84” H. 4 x 3.3 x 7 = 92.4 cu. ft. per pallet 92.4 x 24 = 2217.6 cu. ft. per order
18.2 x 100 = 1820 + 45 = 1865 lbs. per pallet 1865 x 24 = 44,760 lbs. per order
a. You load truck A with the order in #2a above. What percent of the truck’s weight capacity
would the order require? What percent of the truck’s volume capacity would the order require?
17,580/20,000 = .879 = 87.9% of weight 871.2/1228.5 = .709 = 70.9% of volume
b. You load truck B with the order in #2b above. What percent of the truck’s weight capacity
would the order require? What percent of the truck’s volume capacity would the order require?
34,956/38,000 = .9198 = 92% of weight 1716/2152.5 = .797 = 79.7% of volume
c. You load truck C with the order in #2c above. What percent of the truck’s weight capacity
would the order require? What percent of the truck’s volume capacity would the order require?
44760/45000 = .9946 = 99.5% of weight 2217.6/3120 = .7107 = 71.1% of volume
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Quiz: Packing and Loading Calculations Answer Key
1. You receive a packing order for 600 cases of item #401. The case dimensions for this item are
20” L x 15” W x 8” H. The maximum pallet height for the truck delivering this order is 7 feet.
a. What is the total number of cases you can fit on one layer of a 48” x 40” pallet?
48 x 40 = 1920; 20 x 15 = 300; 1920 ÷ 300 = 6.4 → 6 cases per layer
b. How many cases high can you stack this order on a pallet?
7ft. x 12 = 84 in.; 84 ÷ 8 = 10.5 → 10 cases high
c. How many total cases will you stack on one pallet? 6 x 10 = 60 cases per pallet
d. How many pallets will you need for this order? 600 ÷ 60 = 10 pallets
2. You receive a packing order for 500 cases of item #402. You pack 100 cases each on 5
pallets. Each case weighs 16.5 lbs. and each pallet weighs 45 lbs. The maximum loaded
pallet weight for this order is 2000 lbs.
a. What is the weight of one loaded pallet? 100 x 16.5 = 1650 + 45 = 1695 lbs. per pallet
b. Is the weight of the load safe? Yes, 1695 is less than 2000 lbs.
c. What is the total load weight for the entire order? 1695 x 5 = 8475 lbs.
3. A 45 foot truck will hold a maximum of 22 standard pallets. It has a weight limit of 40,000 lbs.
The interior load dimensions for this truck are 44’ L x 7’ W x 7.5’ H.
4. Your order has 20 full pallets and each pallet contains 60 cases. Each case weighs 31.5 lbs.
and each empty pallet weighs 45 lbs. The dimensions for each loaded pallet are 48” L x 40” W
x 85” H.
a. What is the weight and volume of one loaded pallet? 48/12 = 4; 40/12 = 3.3; 85/12 = 7.1; 4
x 3.3 x 7.1 = 93.72 cu. ft. per pallet 93.72 x 20 = 1874.4 cu. ft. per order
5. You load the truck from #3 with the order from #4 above.
a. What percent of the truck’s weight capacity would the order require?
38,700 ÷ 40,000 = .9675 → 96.8%
b. What percent of the truck’s volume capacity would the order require?
1874.4 ÷ 2310 = .811 → 81.1%
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