About this calculator
Compare the full-layer capacity of pallet scenarios using one common carton. Each scenario includes its own deck, tare, height and gross-weight limits, so size is only one part of the comparison.
Inputs
How to use this calculator
Pallet scenario
- Pallet length (in)Scenario footprint, after any required edge clearance.
- Pallet width (in)Zero overhang is assumed.
- Pallet deck height (in)Included in the total-height limit.
- Empty pallet tare (lb)Input measured tare, not pallet structural capacity.
- Maximum total height (in)Overall limit including deck; a scenario below deck height has zero capacity.
- Maximum gross pallet weight (lb)Scenario limit includes all boxes and pallet tare.
Shared inputs
- Box length (in)All scenarios use this same carton.
- Box width (in)Upright cartons may turn 90° on the deck.
- Box height (in)Boxes stay upright; no side laying.
- Gross weight per box (lb)Use the same packaged box weight for each scenario.
- Grid orientationCompare two uniform grid orientations; this is not mixed-direction optimization.
Enter the shipment or scenario values, then select Calculate result.
Method
Formula and variables
For each pallet: TI = best allowed uniform footprint grid. HI = min(floor((height limit − deck) ÷ box height), floor((gross limit − tare) ÷ (TI × box weight))). Capacity = TI × HI. Compare capacities and show all tied leaders; an infeasible scenario returns zero.
- Pallet length (in)
- Scenario footprint, after any required edge clearance.
- Pallet width (in)
- Zero overhang is assumed.
- Pallet deck height (in)
- Included in the total-height limit.
- Empty pallet tare (lb)
- Input measured tare, not pallet structural capacity.
- Maximum total height (in)
- Overall limit including deck; a scenario below deck height has zero capacity.
- Maximum gross pallet weight (lb)
- Scenario limit includes all boxes and pallet tare.
- Box length (in)
- All scenarios use this same carton.
- Box width (in)
- Upright cartons may turn 90° on the deck.
- Box height (in)
- Boxes stay upright; no side laying.
- Gross weight per box (lb)
- Use the same packaged box weight for each scenario.
- Grid orientation
- Compare two uniform grid orientations; this is not mixed-direction optimization.
Interpret the result
The leading scenario has the largest full-layer carton count. A tie does not imply equal footprint efficiency; deck coverage and loaded dimensions remain separate outputs.
Outputs: Full-layer carton capacity, height, weight and coverage by pallet
Full layers only. A partially filled top layer can change the true box maximum. No mixed pattern or physical stacking certification. Footprint coverage is occupied box area per layer ÷ pallet footprint, not outer bounding-box area. Scenarios differ by user-entered limits as well as size.
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
- For the default 48 × 40 in scenario, the best footprint grid is 4 × 4 = 16 boxes.
- Height allows floor((60 − 6) ÷ 8) = 6 layers; weight allows floor(1,950 ÷ 192) = 10 layers.
- Capacity = 16 × min(6, 10) = 96 boxes.
Compare the displayed result
Expected displayed result: 96 boxes
FAQs
Why can a larger pallet have the same capacity?
Whole carton grids and full layers change in steps. Additional deck area may not fit another full grid row or another layer under the entered limits.
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 tare (lb)
- Example: 50
- Maximum total height (in)
- Example: 60
- Maximum gross pallet weight (lb)
- Example: 2000
- Box length (in)
- Example: 12
- Box width (in)
- Example: 10
- Box height (in)
- Example: 8
- Gross weight per box (lb)
- Example: 12
- Grid orientation
- Example: Compare original and 90° rotated gridsOptions: Keep length along equipment / pallet length; Compare original and 90° rotated grids