About the Pallet Calculator
This tool works out how many cartons fit on a pallet using simple column stacking, and how many pallets a shipment needs. It combines two standard warehousing calculations: a footprint (layer) calculation and a stack-height (layers) calculation.
The formulas
- Cartons per layer: divide the pallet's length and width by the carton's length and width, rounding each down to a whole carton (you cannot use a partial carton), then multiply the two counts. The calculator checks the carton in its normal orientation and rotated 90 degrees, and uses whichever orientation packs more cartons:
layer count = max( floor(palletL / cartonL) x floor(palletW / cartonW), floor(palletL / cartonW) x floor(palletW / cartonL) ). - Layers per pallet: divide the maximum stack height by the carton height and round down:
layers = floor(max height / carton height). - Cartons per pallet:
cartons per layer x layers. - Pallets needed: divide the total cartons to ship by cartons per pallet and round up, since a partial pallet still needs its own pallet:
pallets = ceil(total cartons / cartons per pallet).
How to get the best results
- Measure cartons in the same orientation you plan to stack them, and enter the outer (shipping) dimensions, not the product dimensions inside the box
- Pick the pallet type that matches your actual pallet, or use a custom pallet by comparing against the closest standard size
- Set the max stack height to your real limit — trailer clearance, rack opening height, or forklift reach — not just the pallet's own height
Practical context
This calculator assumes simple column stacking (every layer in the same orientation, boxes stacked straight up) and does not check carton weight or the pallet's weight capacity. Real-world loads may use interlocking or brick patterns for stability, and should always be checked against your carrier's or warehouse's weight limits separately.
Frequently Asked Questions
How is cartons per layer calculated?
The calculator divides the pallet's length and width by the carton's length and width, rounding each down to a whole number, then multiplies the two counts together. It checks both the carton's normal orientation and rotated 90 degrees, and keeps whichever fits more cartons per layer.
How many layers fit on a pallet?
Layers equal the max stack height divided by the carton height, rounded down. For example, a 60 inch height limit with 8 inch cartons allows 7 layers (56 inches used), since an 8th layer would push the stack to 64 inches.
Does this include interlocking or brick-pattern stacking?
No. This calculator uses simple column stacking, where every carton in every layer sits in the same orientation directly above the layer below. Interlocking or brick patterns can sometimes fit extra cartons or improve load stability, but they are harder to compute generically and are usually planned with dedicated load-building software.
What are standard pallet sizes?
The most common pallet in North America is the GMA pallet at 48 by 40 inches. The Euro pallet (EPAL/EUR), common across Europe, measures 1200 by 800 millimeters, about 47.24 by 31.50 inches. Pick the type that matches your supply chain, or estimate with the closest standard size.