How do you calculate cases per pallet?

The calculator finds the best single orientation for cases on the pallet footprint, multiplies cases per layer by the maximum number of stackable layers, then applies optional height and weight limits.

Does the calculator mix rotated cases in one layer?

No. It compares lengthwise and widthwise rectangular layouts and uses the better single orientation. Interlocked or mixed pallet patterns can fit differently.

What is included in stack height?

Stack height is pallet height plus the selected number of case layers multiplied by case height.

Is this pallet calculator private?

Yes. Inputs and calculations stay in your browser and are not sent to a server.

Pallet Calculator

Calculate cases per layer, stackable layers, cases per pallet, loaded height, loaded weight, full pallets, and remainder cases from pallet and case dimensions.

Private by design. The calculator runs in your browser and does not store or send shipment inputs.

Inputs

Unit system

Pallet preset

Pallet

Pallet length in

Pallet width in

Empty pallet height in

Empty pallet weight lb

Maximum loaded height in

Maximum loaded weight lb

Case

Case length in

Case width in

Case height in

Case weight lb

Order quantity, cases

Case orientation

Limit layers by maximum loaded weight

Results

Cases per layer:-

Stackable layers:-

Cases per pallet:-

Loaded height:-

Loaded weight:-

Footprint use:-

Full pallets:-

Remainder cases:-

Selected pattern:-

Layer preview

Formula and assumptions

Cases per layer are calculated as floor(pallet length / case length) x floor(pallet width / case width). The calculator also checks the rotated case orientation and uses the selected or best orientation.

Height-limited layers are floor((maximum loaded height - pallet height) / case height). If the weight limit is enabled, weight-limited layers are based on remaining payload weight divided by the weight of one full layer. Cases per pallet are cases per layer x stackable layers.

Assumptions: rectangular cases, no pallet overhang, one orientation per layer, no interlocked or mixed pattern, full layers for maximum pallet count, and uniform case weight. Validate against packaging strength, pallet rating, handling equipment, trailer limits, and site safety rules before shipping.

Example

A 48 x 40 in pallet with 12 x 10 x 8 in cases fits 16 cases per layer. With a 5.5 in pallet and a 60 in loaded height limit, the height allows 6 layers. That gives 96 cases per pallet before checking the optional weight cap.

FAQs

Why is the selected pattern not always the same as turning the case?

The calculator compares the two simple rectangular orientations. The best orientation is the one with the higher case count per layer, with footprint use as a tie-breaker.

Does stack height include the pallet?

Yes. Loaded height equals empty pallet height plus case height multiplied by the number of layers.

Can I plan a partial pallet?

Yes. Enter the order quantity. The results show full pallets and the remaining cases for the final partial pallet.

Can I use centimeters and kilograms?

Yes. Switch the unit system to metric or choose a metric pallet preset. The formulas are unit-neutral as long as dimensions and weights use the selected labels consistently.

How to use the pallet calculator

Choose a pallet preset or enter custom dimensions, then enter the case size and case weight. Set the maximum loaded height and optional weight cap. The planner returns the pallet build and order-level pallet count.

For production planning, compare the result with real packaging tests before finalizing a pallet pattern. Carton strength, stretch wrap, corner boards, pallet condition, forklift handling, warehouse racking, and trailer cube can all change the practical maximum. This tool is best used as an early layout and quantity estimate, then checked against your carrier, customer routing guide, and site safety requirements.

5 Fun Facts about Pallets

The 48 x 40 inch pallet is common in North America. It became popular because it works well for groceries, warehouses, trucks, and forklifts.
Euro pallets use a different footprint. The common 1200 x 800 mm size fits European handling systems and transport patterns.
Turning a case can change the whole layer. A small carton dimension difference can add or remove several cases per pallet.
Stack height includes the pallet itself. The empty pallet height still counts against trailer, rack, and doorway limits.
Weight can beat geometry. A layout may fit by height and footprint but still exceed pallet, forklift, rack, or carrier weight limits.