Pallet Pattern Calculator: Cases per Layer and per Pallet
This calculator tells you how many cases fit on a pallet for a given case and pallet size, and how heavy the finished pallet will be. It compares the two basic orientations, so you can see the difference a few millimetres of case size makes to cases per pallet.
Your numbers
Total extra length and width allowed beyond the pallet. Overhang reduces box strength, so keep it at zero where possible.
Your results
This compares the two single-orientation block patterns only. Pinwheel and interlocked patterns can beat them on awkward sizes, so confirm with pallet pattern software or a trial build before standardising.
Cases per pallet versus max load height (mm)
Sweeps Max load height incl. pallet from 800 to 2200, holding your other inputs fixed.
Check pallet quantities against your ERP
Optional: we compare cases per pallet in your item master with what the warehouse builds.
Optional. The tool and every export work without this. No spam.
How to use the calculator
Pick the pallet size used in your warehouse or customer chain, then enter the outside case size, case weight and the maximum load height including pallet. Enter any allowed overhang. The tool computes the cases per layer for case length along the pallet and for the case rotated, takes the better one, then multiplies by the number of layers that fit under the height limit. Use the chart to see how cases per pallet change with height. Change the case size by a few millimetres to see if a different pattern becomes possible.
- Use outside case dimensions
- Max height includes the pallet
- Common pallets: 1200 x 1000, 1200 x 800, 48 x 40 in
- Keep overhang at zero if the board needs the corner strength
How the pattern is calculated
For each orientation, the number of cases that fit along the length is the pallet length divided by case dimension, rounded down, and the same along the width. Cases per layer is the product. The better of the two orientations is used. Layers equal available height divided by case height, rounded down. Cases per pallet is layers times cases per layer. Area utilisation is the case footprint divided by pallet area, and a result under about 85 percent suggests that a different case size or a mixed pattern would waste less pallet space.
Reading the result
Cases per pallet drives freight cost per case and warehouse space. Compare the result with the weight: a pallet heavy enough to exceed the truck axle or racking limit needs fewer layers. Check the compression strength of the bottom case using the BCT calculator before you rely on a tall stack. Area utilisation under a high target is a prompt to review box dimensions with your supplier, because a small footprint change often gives one more case per layer.
Common mistakes and ERP notes
Frequent errors are using inside box dimensions, ignoring pallet height, assuming overhang is free, and ignoring racking limits. An ERP carries the result as cases per pallet and layers per pallet on the item packaging data, often used for picking and shipping units. Update those fields when case size changes, or your pick tickets and transport plans will use the wrong unit conversions.
- Use outside dimensions of the case
- Respect weight limits for racking and trucks
- Update pallet quantity in the item master when a case changes
- Test the pattern on a real pallet
Frequently Asked Questions
How many boxes fit on a pallet?
It depends on box and pallet size. Divide pallet length and width by case dimensions, round down in each direction, then multiply by the layers allowed by the height limit. Try both orientations and take the larger result.
What is the standard pallet size?
There is no single size. 1200 x 1000 mm is the ISO pallet widely used, 1200 x 800 mm is the Euro pallet, and 1219 x 1016 mm (48 x 40 in) is common in North America. Use the size that your customers and carriers accept.
Is overhang acceptable?
Overhang increases cases per layer but reduces the compression strength of boxes and raises damage risk. Many customers and carriers set maximum limits or prohibit it. Keep it at zero unless your customer agrees and you have tested the stack.
What max height should I use?
Use the lower of the customer's limit, the truck or container height, your racking beam spacing and the stability of the stack. Common limits run from about 1.2 m for retail pallets to 2 m or more for stable industrial loads.
If cases per pallet in your ERP differs from what the warehouse builds, we can check it with a read-only agent over item packaging data. Ask for a short review.
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