Pallet Calculator

How to calculate cartons per pallet (TI × HI)

1. 1. TI: fit the carton's footprint onto the pallet deck. Try it both ways, and try turning part of the layer.
2. 2. HI: take your height limit, subtract the pallet (about 4.75 in for a 48 × 40 wood pallet), divide by the carton height, and round down.
3. 3. Total: multiply TI × HI. For pallets needed, divide the cartons you ship by that total and round up.

Example (loaded above): 16 × 12 × 12 in cartons on a 48 × 40 in pallet, with a 72 in height limit. A plain grid fits 3 × 3 = 9 per layer. Turning the last row lets 10 fit: two rows of 3 one way, plus a row of 4 turned. That covers the whole deck. HI = (72 − 4.75) ÷ 12 = 5.6, so 5 layers. Total: 10 × 5 = 50 cartons, standing 64.75 in tall. At 30 lb a carton plus a 37 lb pallet, it weighs 1,537 lb.

Pallet patterns: why turning some boxes fits more

A straight grid leaves a strip of empty deck whenever the carton does not divide evenly into the pallet. A mixed pattern fills part of the deck in one direction and the rest turned 90°, so that strip gets used. The calculator tries every straight grid and every two-block split and draws the one that fits the most. The two colors in the drawing show the two directions.

How you stack the layers matters too. Column stacking puts each box right on top of the one below, so the strong corners line up. Interlocking, or brick, stacking turns alternate layers to tie the load together, but then box corners sit on weaker panels. Whichever you use, stretch wrap holds the layers in place in transit.

Pallet size, area and height

• • 48 × 40 in (the North American standard): 1,920 sq in, or 13.33 sq ft.
• • Euro 1200 × 800 mm: 0.96 m², about 10.33 sq ft.
• • A standard 48 × 40 wood pallet is about 4.5 to 4.75 in tall, and a Euro pallet 144 mm (5.67 in). It counts toward your height limit and adds its own weight.

More sizes are in the standard pallet size guide, and empty weights by type are in how much a pallet weighs. Height and weight limits differ by carrier and warehouse, so check theirs before you build.

Pallets per truck or container

One layer on the floor. Double-stacking can double these when the freight and the weight limit allow it.

What the pallet costs to ship

An LTL pallet is priced mostly on its freight class, which comes from its density: weight divided by size. Once you know the loaded height and weight, check the pallet density and freight class, then request a freight quote. A shorter, fuller pallet usually costs less to ship than a tall, loose one of the same weight.