Pallet Calculator: How Many Boxes Fit on a Pallet?

Calculation method and assumptions

The optimizer tests uniform 0° and 90° grids plus buildable mixed rows and columns. Each candidate places dimensioned case rectangles inside the effective footprint: pallet length and width plus the allowed overhang on both sides. “Simple rows only” compares the two uniform grids without mixing orientations.

For each valid pattern, TI is the placed case count. Height capacity is floor((maximum loaded height - empty pallet height) / case height). Weight capacity is floor((maximum loaded weight - empty pallet weight) / (TI × case weight)). HI is the lower enabled capacity, and total cases are TI × HI.

Geometric capacity is not a safe-stack approval. The model assumes one rectangular carton size, identical full layers, flat placement, and uniform case weight. It does not model compression strength, interlocking, pinwheel layouts, load balance, stretch-wrap performance, transport forces, or mixed carton sizes.

Worked pallet examples

US example: 48 × 40 inch pallet

For 12 × 10 × 8 in cases weighing 15 lb, 0° gives floor(48/12) × floor(40/10) = 4 × 4 = 16. Turning every case gives floor(48/10) × floor(40/12) = 4 × 3 = 12. The best TI is 16.

With a 5.5 in pallet and 60 in maximum loaded height, cargo height is 60 - 5.5 = 54.5 in, so height permits floor(54.5/8) = 6 layers. A 2,000 lb limit permits floor((2000-45)/(16×15)) = 8 layers. Height is limiting: TI 16 × HI 6 = 96 cases, 53.5 in loaded height, and 1,485 lb. An order of 250 cases needs 3 pallet positions: 2 full pallets and 58 cases on one partial pallet.

Metric example: 1200 × 800 mm Euro pallet

Using centimetres, 30 × 20 × 20 cm cases weighing 10 kg give floor(120/30) × floor(80/20) = 4 × 4 = 16 at 0°, versus floor(120/20) × floor(80/30) = 6 × 2 = 12 at 90°. TI is 16.

With a 14.4 cm, 25 kg pallet, a 160 cm height limit permits floor((160-14.4)/20) = 7 layers. A 1,000 kg limit permits floor((1000-25)/(16×10)) = 6. Weight is limiting: TI 16 × HI 6 = 96 cases, 134.4 cm loaded height, and 985 kg. An order of 300 cases needs 4 pallet positions: 3 full pallets and 12 cases on one partial pallet.

FAQs

How many boxes fit on a 48 x 40 pallet?

It depends on the box footprint and the layer pattern. Divide the usable 48 x 40 inch footprint into buildable 0 and 90 degree placements, then multiply the best cases per layer by the permitted layers. The default 12 x 10 x 8 inch example produces TI 16 and HI 6, or 96 cases.

What does TI-HI mean?

TI is the number of cases on one layer. HI is the number of layers stacked on the pallet. TI multiplied by HI is the total case count on a complete pallet.

Does maximum pallet height include the pallet?

Yes. This calculator treats maximum loaded height as the pallet plus every case layer. Available cargo height equals the maximum loaded height minus the empty pallet height.

How is loaded pallet weight calculated?

Loaded weight is empty pallet weight plus case weight multiplied by the total cases. When the weight limit is enabled, the calculator compares weight-permitted layers with height-permitted layers and uses the lower value.

May boxes overhang a pallet?

Only use overhang when the carrier, customer routing guide, packaging design, and handling process explicitly permit it. Many routing guides prohibit overhang, so the safe default is zero per side.

Why can a real pallet hold fewer boxes than the calculator result?

Geometry is only one limit. Carton compression strength, load stability, pallet rating, uneven weight, stretch wrap, equipment, racking, transport forces, and routing guides can require a lower TI or HI.

How are partial pallets counted?

Full pallets are the order quantity divided by cases per pallet, rounded down. Any remainder creates one partial pallet, so total pallet positions are the order quantity divided by cases per pallet, rounded up.

Does this calculator support mixed carton sizes?

No. It mixes the 0 and 90 degree orientation of one rectangular carton size within a layer, but it does not combine different carton dimensions or test interlocking, pinwheel, stability, or crush strength.

How to use the pallet calculator

1. Choose the pallet. Choose a pallet preset or enter the measured pallet length, width, empty height, empty weight, and permitted overhang.
2. Measure one carton. Enter the outside carton length, width, height, weight, and optional units per case.
3. Set limits and quantity. Enter the maximum loaded height, maximum loaded weight, and order quantity, then choose optimized mixed pattern or simple rows only.
4. Review and verify. Review TI, HI, the proportional layer diagram, height and weight capacity, cases per pallet, and pallets required, then verify the plan against physical and routing constraints.

Practical pallet planning reference

Measure the carton correctly

Measure the closed carton’s longest top edge as length, the other top edge as width, and the base-to-top distance as height. Include bulges, closures, and protective packaging. Use gross packed weight, not product-only weight.

Height, rotation, and packaging strength

Maximum loaded height includes the pallet in this calculator. Rotation helps when a row of 90° cartons fills a strip left by 0° cartons. Even when another layer fits geometrically, compression strength, humidity, stacking alignment, vibration, and load stability may require a lower HI.

Methodology, review, and sources

Maintained by: Starlight Robotics. Last reviewed: 14 July 2026. Model: deterministic rectangular strip packing with 0°/90° placement, full-layer TI-HI, height capacity, optional weight capacity, and equal overhang per side.

Known limitations: The result is geometric and arithmetic planning capacity, not a certification of safe stackability. Carton compression strength, load stability, pallet condition and rating, handling equipment, racks, vehicle limits, and customer routing guides can impose lower limits.

Dimension references: ISO 6780 principal pallet dimensions, European Pallet Association specifications, and Standards Australia AS 4068 preview. Preset maximum weights and loaded heights are editable planning defaults, not claims about every pallet of that footprint.