How this calculator works
A pallet holds whole layers of whole cartons. For one arrangement, divide the pallet length by the carton length and the pallet width by the carton width, round each down and multiply. Turning the cartons a quarter turn gives a second arrangement; keep the better one. The number of layers is the maximum cargo height divided by the carton height. The weight limit is a separate cap: if the maximum load divided by the carton weight is smaller than the volume count, the weight decides and the pallet is only partly filled. The loaded height figure uses whole layers, so a weight-limited load may be one layer shorter than the height limit suggests.
Formula
cartons per layer = floor(pallet length / carton length) x floor(pallet width / carton width), also tried with the carton turned a quarter turn. layers = floor(maximum height / carton height). cartons per pallet = the smaller of (cartons per layer x layers) and floor(maximum load / carton weight).
Worked example
A 1200 by 1000 mm pallet with 400 by 300 by 250 mm cartons: along the length, 1200 / 400 = 3 and 1000 / 300 = 3, giving 9 cartons; turned, 1200 / 300 = 4 and 1000 / 400 = 2, giving 8. The first arrangement wins with 9 per layer. At a 1800 mm cargo height there are 1800 / 250 = 7 layers, so 63 cartons. At 10 kg each that is 630 kg, under the 1000 kg limit.
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Frequently asked questions
Why does the weight limit sometimes decide?
A pallet can be full by volume yet over the weight limit, or light enough to stack higher than the height limit. The smaller of the two counts is the safe load. Dense goods such as liquids and metal parts often hit the weight limit with a partly built stack.
What is a standard pallet size?
The ISO 1200 by 1000 mm pallet is common in Europe and international trade, and the 48 by 40 inch GMA pallet is standard in North America. Both fit standard trucks and roller cages. Choose the size your carrier and warehouse use, because mixed pallet sizes cost space.
Should the pallet itself count in the height?
Many networks state a total height including the pallet, often around 1.6 m for courier and 2.4 m for a trailer. This page measures cargo above the deck, so add the pallet height if the limit includes it. Enter the maximum cargo height that keeps the total legal.
Can cartons overhang the pallet?
Overhang damages cartons and can make the load unstable, and carriers may refuse it or re-stack it at your cost. Keep the load within the pallet footprint, and allow a little tolerance for the stretch wrap.