About the Pallet Calculator
This pallet calculator works out how many boxes or cartons fit on a pallet. It finds the best layer pattern for your box footprint — a straight grid, the grid rotated 90°, or a two-block mixed pattern that combines both orientations — then stacks as many layers as your height limit allows and checks the result against the maximum gross weight.
It is designed for warehouse and shipping teams, e-commerce sellers preparing an Amazon FBA or retailer shipment, and manufacturers designing packaging. The defaults use a standard 48 × 40 in GMA pallet with a 60 in total height limit, which is common for LTL and retail distribution centres; change them for EUR pallets (1200 × 800 mm) or your customer’s routing guide.
Boxes are kept upright (no tipping onto their side) and no overhang is allowed. Use any consistent units: if pallet dimensions are in inches the box dimensions must be in inches too, and box, pallet and maximum weights must share the same unit.
With the default inputs, the boxes per pallet is 50. Change any value above to recalculate instantly.
How to use the pallet calculator
- 1Enter the pallet length, width and deck height.
- 2Enter the maximum total height allowed, including the pallet.
- 3Enter the outside dimensions and weight of one box.
- 4Enter the empty pallet weight and the maximum gross weight.
- 5Read boxes per layer, layers and boxes per pallet, and check the pattern.
Formula and method
The per-layer count is the best of three options: a straight grid floor(L ÷ l) × floor(W ÷ w), the same grid with boxes turned 90°, and two-block patterns where part of the pallet is filled in one orientation and the remaining strip is filled with rotated boxes. Mixed patterns often fit one or two more boxes per layer than a simple grid.
Layers are the whole number of box heights that fit between the pallet deck and the height limit. If the full stack would exceed the maximum gross weight, the box count is reduced to the number the weight limit allows, and the layer count reflects the partial top layer. Boxes are never placed on their side and overhang is not allowed.
- L, W
- Pallet length and width
- l, w, h
- Box length, width and height
- H_max, H_pallet
- Height limit and pallet deck height
- W_max
- Maximum gross weight
Worked examples
16×12×10 in boxes on a 48×40 pallet
A straight grid fits only 9 boxes (3 × 3), but a mixed pattern — two rows of 3 boxes lengthwise plus one row of 4 rotated boxes — fills the 48 × 40 deck exactly with 10. With 54 in of height above the deck, 5 layers of 10 in fit, for 50 boxes and 1,295 lb including the pallet.
EUR pallet with 40×30×25 cm cartons
A 120 × 80 cm pallet fits only 3 × 2 = 6 cartons with the 40 cm side along the length, but turning them 90° fits 4 × 2 = 8, covering the deck completely. 165.6 cm of usable height holds 6 layers of 25 cm, so 48 cartons weigh 576 kg plus a 25 kg pallet.
Heavy boxes limited by weight
Height would allow 50 boxes, but 50 × 60 lb + 45 lb = 3,045 lb exceeds the 2,500 lb limit. (2,500 − 45) ÷ 60 = 40.9, so 40 boxes fit, which is exactly 4 full layers at 2,445 lb.
Frequently asked questions
How many boxes fit on a pallet?+
Divide the pallet footprint into the box footprint to get boxes per layer, choosing the best orientation or a mixed pattern, then multiply by the number of layers that fit under the height limit. A 48 × 40 in pallet holds 10 boxes of 16 × 12 in per layer.
What is the standard pallet size?+
In North America the most common is the 48 × 40 in GMA pallet, about 5–6 in tall. In Europe the EUR/EPAL pallet is 1200 × 800 mm and 144 mm tall, and the ISO 1200 × 1000 mm pallet is also common.
How high can a pallet be stacked?+
Many carriers and retail distribution centres limit pallets to about 60 in (152 cm) including the pallet, though some allow up to 72 in or more. Always check the routing guide or carrier rules, because over-height pallets may be refused or charged extra.
Should boxes overhang the pallet?+
No. Overhang reduces carton compression strength significantly and can lead to crushed boxes and damage claims, so this calculator never allows it. Underhang of up to an inch or so is acceptable and often preferred.
What is a mixed or pinwheel pallet pattern?+
It combines boxes in two orientations in the same layer to use space a straight grid would waste. This calculator tests two-block patterns; more complex pinwheel patterns can sometimes fit one more box, and interlocking layers improve stability.