Pallet & Carton Calculator

How the Pallet Calculator works

Enter your pallet size, carton size and limits, and the calculator finds the layer pattern that fits the most cartons, then calculates layers, total cartons, load height, gross weight and deck coverage. It tests both orientations and mixed "block" patterns where part of the layer is rotated to use leftover space.

Inputs

• Pallet: 48 × 40 in GMA (the US standard), 42 × 42, 48 × 48, EUR 1200 × 800 mm, 1200 × 1000 mm or custom
• Carton outside dimensions
• Maximum load height including the pallet (commonly 60–72 in for freight; check your carrier or warehouse)
• Carton weight and maximum pallet weight
• Allowed overhang (best kept at zero)
• Mixed orientation on or off

The calculator assumes a pallet height of about 5.5 in and a pallet weight of about 45 lb.

Tips for efficient pallets

• Design cartons around the pallet. A carton footprint that divides evenly into 48 × 40 in wastes less space.
• Avoid overhang. Cartons hanging over the edge lose a large share of their compression strength.
• Prefer column stacking for strength; use interlocking patterns only when stability requires it, and check strength with the Box Strength Calculator.
• Respect weight limits for pallets, racking and trucks.
• Use corner boards and stretch wrap for stability.

Standard pallet sizes

The 48 × 40 in pallet is the default in the calculator because it is the most common in the United States. If your warehouse, carrier or customer uses another size, enter it instead.

Example layouts on a 48 × 40 pallet

Using the same logic as the calculator, here is how common case sizes fit on a 48 × 40 in pallet with a 54 in load height above the deck:

The calculator also tests mixed orientations within a layer, which can sometimes fit more cases than a single orientation. Small changes to case dimensions can add or remove a whole row, so check pallet fit when you design shipping cases.

Load height and weight limits

Pallet height is limited by trucks, racks, warehouse rules and stability. Many shippers keep full pallets somewhere around 48 to 72 in tall including the pallet, and many retailers and carriers publish their own maximums. Weight limits depend on the pallet, the racking and the receiving rules. Before designing a pallet pattern, ask your carrier, warehouse or customer for their height and weight limits.

Column vs. interlocked stacking

Column stacking lets boxes carry load through their strong corners. Interlocking ties layers together but places corners over weaker panel centers. A common compromise is column stacking with stretch wrap and corner boards, or interlocking only the top layers.

Overhang and underhang

Boxes should not hang over the pallet edges. Overhang removes support from box edges and corners, cutting compression strength and exposing boxes to damage from forklifts and neighboring pallets. Underhang, when the load is smaller than the pallet, is safer for strength but wastes space and can let the load shift. The best patterns fill the pallet footprint closely without exceeding it.

Securing the load

• Stretch wrap holds the load together. Wrap from the pallet base upward, overlapping layers.
• Corner boards protect edges and add vertical strength.
• Tier sheets between layers spread weight and stabilize column stacks.
• Top caps protect the top layer and distribute strapping pressure.
• Strapping secures heavy or tall loads.

Labeling pallets

Label each pallet on at least two adjacent sides with the shipment details your carrier or customer requires: shipper and consignee, purchase order, carton count and pallet number. Retailers often require specific shipping labels with barcodes. Clear labels speed receiving and reduce lost freight.

Freight cost and density

Less-than-truckload (LTL) freight pricing often depends on freight class, which considers density (weight per cubic foot) among other factors. Denser pallets generally ship at lower rates per pound than light, bulky pallets. Efficient pallet patterns, right-sized cases and full use of pallet height all improve density and reduce cost per unit shipped. Ask your freight provider how your shipment will be classified.

Containers and floor loading

For international or long-distance shipments in containers, products may be palletized or floor-loaded. Palletized loads are quicker to handle but use space for the pallets themselves. Floor-loaded cases fill the container more completely but take longer to load and unload. Container interior dimensions vary by type, so plan case sizes and pallet patterns with your forwarder.

Designing cases for pallet efficiency

When designing shipping cases, check pallet fit early:

1. Start with the product and inner packaging.
2. Choose a case count that suits orders and handling weight.
3. Test case dimensions in the calculator on your pallet size.
4. Adjust by small amounts to add rows or layers.
5. Check box strength for the stack height with the box strength calculator.

Common pallet mistakes

Overhanging cases. They lose strength and get damaged.

Exceeding height limits. Pallets may be rejected or re-worked at your cost.

Weak bottom cases. The bottom layer carries everything above.

Poor wrapping. Loads shift and collapse in transit.

Ignoring receiving rules. Retailers and fulfillment centers often have strict requirements.

Ti-Hi: the language of pallet patterns

Warehouses and retailers describe pallet patterns with two numbers, often written as Ti × Hi. Ti (tier) is the number of cases in one layer. Hi (high) is the number of layers. A 9 × 5 pallet has nine cases per layer and five layers, for 45 cases. Retailers often specify the Ti-Hi they expect for each product so that pallets arrive consistently and fit their racks and processes. If you supply retailers, ask for their requirements and design your case size to meet them.

How the calculator chooses an orientation

For each layer, the calculator tests the case in both orientations on the pallet footprint and, where useful, combinations of orientations in different zones of the layer. It chooses the arrangement with the most cases that stays within the pallet edges. It then divides the available load height by the case height to find the number of layers. You can compare results by adjusting case dimensions slightly; sometimes a quarter inch makes the difference between two rows and three.

Calculating pallet weight

Total pallet weight is the number of cases multiplied by the weight of one packed case, plus the pallet itself and any wrap, corner boards or tier sheets. A wooden 48 × 40 pallet commonly weighs around 30 to 50 lb, while plastic pallets vary. Compare the total with your carrier's and warehouse's limits, and with the strength of the bottom cases. Heavy loads may need fewer layers even when height allows more.

Pallet types

Stringer pallets use long boards (stringers) to support the deck. They are common and economical. Many allow forklift entry from two sides, with notches enabling partial four-way entry.

Block pallets use blocks between the decks, allowing true four-way entry by forklifts and pallet jacks. They are sturdier and common in retail supply chains and pallet pooling programs.

Plastic pallets are durable, washable and consistent in weight, and are used in hygienic or closed-loop systems.

Export pallets made of wood must usually be heat-treated and marked under international phytosanitary standards to prevent pests crossing borders. If you export, confirm requirements with your forwarder.

Mixed pallets

When a pallet carries several products, the pattern needs more care. Place the heaviest and strongest cases at the bottom, keep layers as level as possible, and fill gaps so the load does not shift. Some retailers accept mixed pallets only with specific labeling or layer arrangements. Mixed pallets are common for smaller brands shipping to fulfillment centers, so plan case sizes that combine well.

Pallet footprint utilization

Footprint utilization measures how much of the pallet surface the cases cover. A pattern that covers most of the deck uses space efficiently and stacks more stably. Large gaps waste freight space and let cases shift. When designing case sizes, aim for patterns with high footprint coverage and no overhang. The calculator's layout view makes gaps easy to see.

Worked example: a coffee brand's pallet

A coffee brand ships 12 bags in a 16 × 12 × 10 in case weighing 14 lb. On a 48 × 40 pallet with a 54 in load height, the calculator shows nine cases per layer and five layers, for 45 cases. The pallet weighs about 630 lb in cases plus the pallet and wrap. The brand checks the bottom case strength: four cases above weigh 56 lb, so even with a conservative safety factor, standard 32 ECT board is suitable. A distributor asks for a slightly lower height, so the brand drops to four layers and 36 cases per pallet.

Preventing damage on pallets

• Keep cases within the pallet footprint.
• Use column stacking with wrap and corner boards for maximum strength.
• Add tier sheets for heavy or unstable loads.
• Wrap tightly from the base and secure the load to the pallet.
• Do not double-stack pallets unless the bottom cases are designed for it.
• Mark pallets clearly if they must not be stacked.

Shipping to fulfillment centers and retailers

Fulfillment centers and large retailers often publish inbound pallet requirements, including pallet type, maximum height and weight, labeling and whether mixed products are allowed. Requirements differ between companies and change over time. Check the current guide before each first shipment, and keep a simple checklist for your team.

When to palletize and when to ship parcels

Small brands often start by shipping everything as parcels. As volumes grow, palletized freight becomes cheaper for bulk movements: stock going to a warehouse, a fulfillment center, a retailer's distribution center or a market stall. A rough rule is that once a shipment fills a meaningful part of a pallet, freight quotes are worth comparing with parcel rates. Pallets also reduce handling, because cases move as one unit rather than as dozens of separate parcels that can be lost or damaged.

Designing shipping cases for pallets

Pallet efficiency starts with the shipping case, sometimes called the master carton. When designing it, consider:

• Units per case: a count that matches how customers or retailers order, such as 6, 12 or 24.
• Case weight: light enough for one person to lift safely. Many companies keep cases well under 50 lb.
• Footprint: dimensions that divide evenly into the pallet size, with no overhang.
• Height: a height that stacks to the target load height without wasted space.
• Strength: board strong enough for the bottom case to carry the stack above it.
• Labels: space for case labels and barcodes on at least two sides.

Inner packs and shelf-ready cases

Some retailers prefer inner packs, smaller bundles inside the master carton, so stores can order in smaller quantities. Others prefer shelf-ready cases that open into a display tray. Both affect case dimensions and pallet patterns. If you supply retail, confirm the case format early so you design the product packaging, inner packs and master cartons together.

Stretch wrapping well

A pallet that is wrapped well arrives intact. Start by wrapping the base of the load to the pallet deck several times, then spiral upward with an overlap between passes, and finish with extra wraps at the top. Keep tension firm but not so tight that it crushes corners. Corner boards under the wrap protect edges and spread pressure. Machine wrapping gives the most consistent results; hand wrapping works for small volumes if done carefully.

Rack clearance and warehouse rules

Warehouses store pallets in racks with fixed openings. A pallet that is a few inches too tall may not fit a rack position and will need to be broken down at your cost. Ask your warehouse for its maximum pallet height and weight per position. Build pallets slightly below the maximum to allow for pallet height variation and settling.

What to tell a freight carrier

To get an accurate LTL freight quote, provide the number of pallets, pallet dimensions including height, total weight, pickup and delivery locations, whether there is a loading dock or a liftgate is needed, the type of goods and any special requirements such as appointments or inside delivery. Accurate information avoids reclassification fees and surprise charges after delivery.

Cost per unit shipped

To compare shipping options, divide the total freight cost by the number of units on the pallet. A pallet of 45 cases with 12 units each carries 540 units. If the freight cost is spread across 540 units, the per-unit cost can be far lower than shipping the same units as parcels. Efficient patterns that add one more layer or a few more cases per layer lower this number directly.

More pallet FAQ

How many boxes fit on a pallet?

It depends on case size, pallet size and height limit. Enter your case dimensions in the calculator to see the exact Ti-Hi and total.

Should I use the same case for parcels and pallets?

Often yes, if the case is strong enough for both. Parcel shipping adds drops and conveyor impacts, so test both journeys.

Can I stack pallets on top of each other?

Only if the bottom pallet's cases are strong enough and the receiving warehouse allows it. Many shippers mark pallets "Do not stack" to prevent crushing.

What is a pallet tie sheet or slip sheet?

A tier sheet sits between layers to stabilize them; a slip sheet replaces a pallet for some automated handling systems. Ask your customer if either is required.

Cartons per GMA pallet (48 × 40 in) for common carton sizes

Simple column-stacked patterns on a 48 × 40 in pallet with no overhang and a 60 in maximum load height including a 5.5 in pallet. The calculator above also tests mixed orientations, which can fit more cartons.

Check weight limits: total load weight must stay within your pallet, racking and carrier limits.