About this calculator
The number of cartons per pallet drives several decisions at once: how many pallets to order, how many go into a container or truck, and how many rack positions a warehouse uses. Warehouses and overseas buyers often set a maximum pallet height (for example 1.8 m including the pallet) and overhang limits, so a stack that looks neat on the factory floor can still be rejected at receiving.
This calculator builds the load layer by layer on the pallet base. For each layer it looks for the best pattern by turning cartons 90°, including mixed patterns that often beat a plain column stack. The number of layers comes from the maximum height minus the pallet height, divided by the carton height. By default cartons stay upright, because most cartons are designed to carry load that way. You can allow overhang per side (or a negative value for underhang), cap the number of layers and enter the weight per carton so the total is capped by the pallet's load rating.
Built-in pallet data, such as a 150 mm height, 25 kg tare and 1,500 kg maximum load for a 1200 × 1000 pallet, are typical values. Real pallet ratings differ for static loads, forklift handling and racking, so check your pallet supplier's specification. The stacking strength of the cartons also needs a separate check, for example with the box stacking calculator.
Worked example
Cartons of 400 × 300 × 250 mm weighing 8 kg on a 1200 × 1000 pallet (150 mm high, 25 kg tare), maximum height 1.8 m:
- Per layer: 4 cartons turned (300 mm lengthwise) in a 400 mm strip + 3 × 2 cartons in the 600 mm strip = 10 per layer (100% of the base)
- Stacking space: 1,800 − 150 = 1,650 mm → 1,650 ÷ 250 = 6 layers
- Total: 10 × 6 = 60 cartons, height 6 × 250 + 150 = 1,650 mm
- Gross weight: 60 × 8 = 480 kg + 25 kg pallet = 505 kg
This pallet is limited by height, not weight: it stays well below the 1,500 kg maximum load.
How to use it
Choose the pallet
Pick a 1200 × 1000, euro 1200 × 800 or 1100 × 1100 pallet, or enter your own size, height, tare and maximum load.
Enter the carton
Fill in the carton's outer dimensions and weight, then the maximum loaded pallet height required by the warehouse or buyer.
Set overhang and orientation
Enter overhang per side if allowed, a layer limit if needed, and keep cartons upright unless the contents can lie on their side.
Read the result and continue
See cartons per layer, layers, total cartons, height and gross weight, then move on to pallets per container or the 3D Planner.