Choose the pallet, enter the carton size and weight, and set the maximum load height and weight. The calculator finds the best layer pattern, including mixed orientations.
Cartons per pallet
cartons
Cartons per layer
Layers
Load height
Gross weight
Pallet area used
%
How the pallet pattern is found
The calculator first fills one layer. It tries all cartons facing the same way, all turned by 90°, and mixed patterns where one block of cartons faces one way and the rest are turned. The pattern with the most cartons wins. Then it stacks as many layers as fit under the height limit:
Cartons = cartons per layer × layers, but not more than weight limit ÷ carton weight
Worked example
Cartons of 16 × 12 × 10 in, 20 lb each, go on a 48 × 40 in pallet. Lengthwise, 3 × 3 = 9 cartons fit per layer; turned, 4 × 2 = 8. A mixed pattern, two rows of 3 lengthwise and one block of 4 turned in the remaining 16 in, gives 10 per layer and uses all 1,920 in² of the pallet. With a 60 in height limit and a 6 in pallet, 5 layers fit: 50 cartons, 1,040 lb gross, 56 in high.
Divide the pallet length and width by the box length and width, round down and multiply, then try the box turned by 90° and mixed patterns. Multiply the best layer by the number of layers that fit under the height limit. The weight limit can cap the total.
What are standard pallet sizes?
US: 48 × 40 in (GMA pallet). Europe: Euro pallet 120 × 80 cm (EPAL). UK and industrial: 120 × 100 cm. Australia: 116.5 × 116.5 cm. Asia often uses 110 × 110 cm.
How high can a pallet be stacked?
It depends on the carrier, the truck and the racking. A common limit is 60 to 72 in (about 150 to 180 cm) including the pallet for LTL freight, and up to 2.6 m in a full European trailer. Check with your carrier or warehouse.
Does the calculator allow overhang?
No. Cartons stay within the pallet edges, which is what most carriers and warehouses require. Overhang damages cartons and can raise the freight class or the loading meter charge.