About this calculator
Use this tool to estimate the number of identical upright cartons on one pallet, then translate an order into full and partial pallets. It compares uniform footprint grids and keeps only complete layers.
Inputs
How to use this calculator
Pallet and load
- Pallet length (in)Enter the usable deck length.
- Pallet width (in)Enter the usable deck width.
- Pallet deck height (in)Included in the total-height limit.
- Empty pallet weight (lb)Used to calculate gross pallet weight.
- Maximum total height (in)Measured from the floor, including the pallet deck.
- Maximum gross weight (lb)Includes the pallet and products.
Carton and order
- Box length, width and height (in)Use the outside carton dimensions.
- Box weight (lb)Use packaged gross weight per box.
- Boxes to shipOptional; leave blank to calculate one pallet only.
- Allow box rotationCompare the original and 90-degree footprint orientations.
Enter the shipment or scenario values, then select Calculate result.
Method
Formula and variables
Boxes per layer = the best allowed rectangular grid on the pallet footprint. Layers = the lesser of full layers allowed by total height and the gross-weight limit. Pallet capacity = boxes per layer × full layers.
- Pallet length (in)
- Enter the usable deck length.
- Pallet width (in)
- Enter the usable deck width.
- Pallet deck height (in)
- Included in the total-height limit.
- Empty pallet weight (lb)
- Used to calculate gross pallet weight.
- Maximum total height (in)
- Measured from the floor, including the pallet deck.
- Maximum gross weight (lb)
- Includes the pallet and products.
- Box length, width and height (in)
- Use the outside carton dimensions.
- Box weight (lb)
- Use packaged gross weight per box.
- Boxes to ship
- Optional; leave blank to calculate one pallet only.
- Allow box rotation
- Compare the original and 90-degree footprint orientations.
Interpret the result
Capacity is the number of cartons on a full pallet under both entered limits. Loaded height includes the deck, and gross weight includes pallet tare. Any boxes left after filling the full pallets go on one partial pallet.
Outputs: Boxes per layer, layers, capacity, height and gross pallet weight
A rectangular full-layer grid estimate only. It does not certify load stability, carton strength, pallet structural capacity, axle loading, or carrier acceptance.
Worked example
Check the arithmetic
This example uses the starting values shown above. The arithmetic below is calculated independently of the interactive result.
Work through the calculation
- Original grid: floor(48 ÷ 12) × floor(40 ÷ 10) = 4 × 4 = 16 boxes per layer; the rotated grid gives 12.
- Height allows floor((60 − 6) ÷ 8) = 6 layers. Weight allows floor((2,000 − 50) ÷ (16 × 12)) = 10 full layers.
- Use the lower layer count: 16 × 6 = 96 boxes. Height = 6 + 6 × 8 = 54 in; gross weight = 50 + 96 × 12 = 1,202 lb.
- An order of 250 boxes needs ceil(250 ÷ 96) = 3 pallets: 2 full pallets and 58 boxes on a partial pallet.
Compare the displayed result
Expected displayed result: 96 boxes
FAQs
Why does unused space remain above the load?
The model rounds down to complete carton layers. Extra space smaller than one carton height cannot add a layer, and the gross-weight limit may stop stacking earlier.
Example inputs and options
Starting values are examples unless a field identifies a dated rule. Unit selectors convert only fields marked for conversion. Rates and model options keep the units and basis shown in their labels.
- Pallet length (in)
- Example: 48
- Pallet width (in)
- Example: 40
- Pallet deck height (in)
- Example: 6
- Empty pallet weight (lb)
- Example: 50
- Maximum total height (in)
- Example: 60
- Maximum gross weight (lb)
- Example: 2,000
- Box length, width and height (in)
- Example: 12 × 10 × 8
- Box weight (lb)
- Example: 12
- Boxes to ship
- Example: 250
- Allow box rotation
- Example: YesOptions: Yes; No