Work out how many cartons fit on a pallet. Enter the pallet and box dimensions plus your height and weight limits, and get boxes per layer, number of layers, total boxes per pallet, the layer pattern and how well the pallet is used.
Last updated:
Units
Pallet
in
in
in
A wooden 48 × 40 in pallet is about 5–6 in tall.
lb
Optional. Wood pallets weigh roughly 30–50 lb.
Carton (box)
in
in
in
lb
Optional, needed for the weight limit.
Limits
in
Includes the pallet. Many warehouses and carriers cap loads at 48–72 in.
lb
Includes the pallet. Leave empty for no limit.
in
0 = cartons stay within the pallet edges (recommended).
cartons
Shows how many pallets you need.
Carton orientation
Enter your values to see the result.
Advertisement
Advertisement
How to use the Pallet Calculator
Choose units: inches & pounds or centimeters & kilograms, or tap a pallet preset.
Enter the pallet length, width, deck height and empty weight.
Enter the carton outside length, width, height and weight.
Set the limits: maximum load height from the floor, maximum gross weight and any overhang you allow.
Press Calculate to see boxes per pallet, the layer pattern and the orientation comparison; add a carton count to get the number of pallets.
The pallet loading formula
Boxes per layer = ⌊pallet length ÷ box length⌋ × ⌊pallet width ÷ box width⌋, also tried with the box turned 90°. A two-block pattern (part of the layer one way, the rest turned) often fits one or two more.
Boxes per pallet = min(boxes per layer × layers, weight cap)
Pallets needed = ⌈cartons to ship ÷ boxes per pallet⌉
Example: 15 × 11 × 9 in cartons on a 48 × 40 in pallet. A plain grid fits 3 × 3 = 9 or 4 × 2 = 8 per layer, but turning one strip of cartons gives 10. With a 60 in limit: ⌊(60 − 5.5) ÷ 9⌋ = 6 layers, so 60 cartons per pallet, 1,080 lb of product plus the pallet.
Common pallet sizes
Pallet
Size
Typical use
GMA / grocery
48 × 40 in (1219 × 1016 mm)
Most common in the US and Canada
EUR / EPAL 1
1200 × 800 mm (47.2 × 31.5 in), 144 mm tall
Europe, retail
ISO industrial (EUR 2)
1200 × 1000 mm (47.2 × 39.4 in)
Europe, industrial goods
Square
42 × 42 in (1067 × 1067 mm)
Telecom, paint, drums
Square
48 × 48 in (1219 × 1219 mm)
Drums, bulk bags
Australian standard
1165 × 1165 mm
Australia
Asia
1100 × 1100 mm
Japan, Korea, much of Asia
Tips for building a stable pallet
Measure the outside of the carton and round up a little; bulging cartons rarely match the spec sheet.
Column stacking (cartons directly on top of each other) keeps the most compression strength; interlocking (alternating the pattern each layer) is more stable but weaker. Many shippers interlock only the top layers or use stretch wrap and corner boards instead.
Put the heaviest cartons at the bottom and keep the top flat so pallets can be stacked if the carrier allows it.
Check the freight class of the finished pallet: a denser pallet usually ships at a lower class. Use the Freight Class Calculator with the loaded height and gross weight.
Frequently asked questions
How do I calculate how many boxes fit on a pallet?
Find the boxes per layer by dividing the pallet length and width by the box footprint (try both box orientations and keep the higher count). Then find the number of layers: (maximum load height − pallet height) ÷ box height, rounded down. Boxes per pallet = boxes per layer × layers, unless the weight limit allows fewer.
How many boxes fit on a 48 × 40 pallet?
It depends on the box size. For example, 16 × 12 × 10 in cartons fit 9 per layer in a simple grid and 10 per layer with a mixed pattern on a 48 × 40 in pallet. With a 60 in height limit and a 5.5 in pallet, 5 layers fit, so 50 cartons per pallet if the weight allows.
What is the standard pallet size?
In North America the most common pallet is the GMA pallet, 48 × 40 in, about 5.5 to 6 in tall. In Europe the EUR / EPAL pallet is 1200 × 800 mm and 144 mm tall, and the ISO industrial pallet is 1200 × 1000 mm. Other ISO sizes include 1165 × 1165 mm (Australia) and 1100 × 1100 mm (Asia).
What is the maximum height for a pallet?
There is no single rule. Many warehouses and LTL carriers prefer loads up to about 60 to 72 in (1.5 to 1.8 m) including the pallet, and racking or trailer door height may limit it further. Check your carrier's and your receiver's requirements before you build the load.
How much weight can a pallet hold?
A typical wooden 48 × 40 in pallet can carry roughly 2,500 lb dynamic (being moved) and more when static, while a EUR pallet is commonly rated around 1,500 kg dynamic. Ratings depend on the pallet's build and condition, and the safe load is limited by the cartons' strength too.
Why should I avoid pallet overhang?
Cartons hanging past the pallet edge lose support at their corners, where most of their stacking strength is, so they can crush or tear. Overhang also gets cartons snagged by forklifts and other pallets. Keep cartons within the edges where possible, and use this calculator's overhang field only for the small amount your shipper allows.
What is pallet cube utilization?
Cube utilization is the carton volume on the pallet divided by the available space (pallet area × usable stacking height). Higher utilization means fewer pallets and lower freight cost. Footprint (area) utilization looks at one layer only: carton area divided by pallet deck area.
Are all the tools on FreeToolCabin tested for quality and accuracy?
Yes! Every tool on our site undergoes automated Q/A testing in real browser environments to ensure high precision, correct output, and zero errors. If you happen to spot a bug or have a suggestion, please contact us at [email protected] and our team will review it right away.