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Pallet Load Calculator: Cases per Pallet

This pallet load calculator tells you how many cartons fit on one pallet once you apply the real limits: the footprint, the height cap and the weight cap. Use it to set standard pack quantities, quote freight, or check a supplier's stated cases per pallet.

Your numbers

in

48 x 40 in is the common GMA pallet.

in
in
in
in
in
in

Set by truck, rack beam level or customer rule.

lb
lb

Excluding the pallet itself.

Your results

Cartons per pallet
45
The lower of the height limit and the weight limit.
Product weight per pallet
810
Cartons per layer, pattern A (length along length)
9
Cartons per layer, pattern B (rotated 90 degrees)
8
Best cartons per layer
9
Simple block patterns only; pinwheel patterns can sometimes add a carton.
Layers that fit under height limit
5
Cartons limited by height
45
Cartons limited by weight
111
Pallet footprint used
90%
Low values mean wasted deck area or an overhang opportunity.

Geometry check only. Confirm crush strength, overhang rules, stretch wrap and carrier limits before changing a pallet pattern.

Save results:

Cartons per pallet vs carton height

Sweeps Carton height from 4 to 20, holding your other inputs fixed.

Check packaging data in your ERP

Optional: have an expert compare ERP pallet quantities and units of measure against real pack-outs.

Optional. The tool and every export work without this. No spam.

How to use it

Enter the pallet and carton dimensions in the same unit, then the maximum loaded height and the maximum product weight. The calculator tests the two basic orientations for a layer, picks the better one, stacks as many layers as the height allows and then caps the total at the weight limit. Set the maximum height from the tightest constraint in your chain, such as a rack beam opening or a customer receiving rule, not just the truck.

  • Measure outside carton dimensions, including bulge
  • Subtract the pallet deck height from the height limit
  • Use product weight excluding the pallet
  • Round carton sizes up, never down

The method

Cartons per layer is the product of how many cartons fit along the pallet length and how many fit across the width, using whole numbers only. Rotating the carton 90 degrees gives a second pattern, and the larger wins. Layers equal the available height divided by carton height, rounded down. The load is the lower of the height-limited count and the weight-limited count. Footprint use shows how much of the deck the pattern covers; below roughly 90 percent there may be room to change carton size.

Worked example

A 48 by 40 in pallet with a 16 by 12 by 10 in carton gives 3 by 3 in pattern A and 4 by 2 in pattern B, so 9 and 8 cartons per layer. With a 60 in cap and a 5.5 in deck, 5 layers fit, giving 45 cartons. At 18 lb each that is 810 lb, well under a 2,000 lb limit, so height is the constraint. If a design change raised the carton height to 11 in, only 4 layers would fit, and the pallet would drop to 36 cartons. That kind of cliff is exactly what the chart shows.

Common mistakes

Teams often forget that a pallet quantity entered in the ERP must match the real pallet build, otherwise ASN, picking and freight data drift apart. Others ignore crush strength: stacking five layers can fail on a lower layer even when geometry works. Mixed-SKU pallets, overhang, and column-stack versus interlock patterns are not modelled here. In SAP, Oracle, Infor or Epicor, store the result as the unit of measure conversion for the pallet, and record the pattern in the packaging instruction.

Frequently Asked Questions

How many boxes fit on a standard pallet?

It depends on box size, height limit and weight. A 48 by 40 inch pallet commonly takes 8 to 12 cartons per layer for mid-sized boxes, and total height is usually capped near 48 to 72 inches depending on the carrier or rack.

What pallet size should I enter for Europe?

The EUR pallet is 1200 by 800 mm, or about 47.2 by 31.5 inches. Enter both in the same unit as your carton dimensions, for example all in millimetres, and set the height limit accordingly.

Does this include the weight of the pallet?

No. Enter the maximum product weight, which is the pallet capacity minus the pallet itself and any wrap or dunnage. Add pallet weight afterwards when calculating gross shipping weight.

Can a pinwheel pattern fit more cartons?

Sometimes. Pinwheel and mixed patterns can add a carton or two when the footprint has leftover space. This calculator tests the two block orientations only, so treat the result as a safe minimum.

If your pallet quantities in the ERP no longer match what is built on the floor, Netray can help check unit-of-measure and packaging data across your items.

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