Introduction
This pallet calculator shows you how many boxes fit on one pallet. Type in your box size, pick a pallet, and set your height limits.
It tests all six ways a box can sit on the pallet and picks the one that holds the most cartons. You get the boxes per layer, the number of layers, the total box count, the loaded height, and the total weight. It also warns you if the stack is too tall or too heavy.
You can choose a stacking pattern (row, brick, or pinwheel), allow overhang, and rotate or mirror layers to lock the load together. Presets cover common pallets like the EUR 800 × 1200 mm and the US 48 × 40 in. Work in mm, cm, m, inches, or feet, and in kg, grams, tons, pounds, or ounces.
Results come with a 2D top-down layout drawn to scale, a 3D view you can spin, a step-by-step solution, charts, and a layer-by-layer table. You can save it all as a CSV or PDF. Use it to plan shipments, cut wasted space, and lower freight costs.
How to use our Pallet Calculator
Enter your box size, pallet size, and height and weight limits, and this pallet calculator shows how many boxes fit per layer, how many layers fit, total boxes per pallet, loaded height, load weight, and packing efficiency with 2D and 3D diagrams.
Global dimension unit: Pick mm, cm, dm, m, in, or ft. This changes every length box at once and converts the numbers for you.
Global weight unit: Pick kg, g, t, lb, or oz. This changes every weight box at once and converts the numbers for you.
Show length results in: Choose the unit you want for heights, footprints, and the worked steps.
Show weight results in: Choose the unit you want for load weight and capacity checks.
Box width: Type the side-to-side size of one carton.
Box length: Type the front-to-back size of one carton.
Box height: Type how tall one carton stands when stacked.
Box weight: Type the full weight of one packed carton. Leave it blank to skip weight checks.
Pallet type preset: Pick a common pallet, like a EUR 800 × 1200 mm or a US 48 × 40 in pallet. Choose Custom to type your own size.
Pallet width: Type the pallet deck size across the X axis. Typing here sets the preset to Custom.
Pallet length: Type the pallet deck size along the Y axis. Typing here sets the preset to Custom.
Pallet deck height: Type how thick the empty pallet is, not the load.
Maximum stack height: Type the tallest the whole load can be, pallet included. This often matches your truck or rack limit.
Maximum cargo height: Type the tallest the boxes alone can be above the deck. The calculator uses the stricter of the two height limits.
Max pallet capacity: Type the weight the pallet can hold. Leave it blank to skip the check.
Stacking mode: Keep Simple to test all 6 box turns and find the best one.
Units per layer: Choose Auto to let the tool count the boxes that fit, or Manual to set your own number.
Boxes per layer (manual): Type how many boxes go in one layer. You get a warning if that many will not fit.
Number of layers: Type how many layers you want to stack. If it is too many, the tool uses the max that fits.
Stacking pattern: Pick Row for a plain grid, Brick for offset rows that hold better, or Pinwheel for locked corners.
Overhang: Turn this on if boxes may hang past the pallet edge, then type how much per side. The limit is 152 mm (6 in).
Layer-to-layer alignment: Pick Parallel for same layers, Rotated 90° to turn every other layer, or H-Mirrored or V-Mirrored to flip them for a tighter, safer stack.
Press Calculate to see your results, Reset to start over, or Export CSV or Export PDF to save the pallet load plan.
Pallet Loading Explained
A pallet is a flat wooden or plastic base that holds boxes so a forklift can lift them. When you ship goods, you stack boxes on a pallet, wrap them, and send the whole unit. Working out how many boxes fit on one pallet is called palletizing or pallet loading. It tells you how many pallets a shipment needs, and that sets your freight cost.
Common Pallet Sizes
- EUR / EUR-1: 800 × 1200 mm, the standard pallet in Europe
- US standard (GMA): 1219 × 1016 mm (48 × 40 in), most common in North America
- Australian: 1165 × 1165 mm
- Asian: 1100 × 1100 mm
- Half pallets: 800 × 600 mm or 610 × 1016 mm, used for small retail displays
Most pallets are about 150 mm (6 in) thick. That thickness counts toward your total height, so you must add it in.
Box Orientation
A box can sit on a pallet six different ways, because any of its three sides can face up. Each way gives a different footprint and a different box height. One choice almost always fits more boxes than the others, so it pays to test all six.
Stacking Patterns
- Row: a plain grid. Fast to build and easy for robots, but the layers do not lock together.
- Brick (offset): every second row shifts half a box over, like bricks in a wall. This grips better and cuts down on tipping.
- Pinwheel: four groups of boxes turn around a center block. It interlocks well and often uses odd corner space.
You can also turn each new layer 90° or mirror it. Turning layers helps tie the stack together so it does not slide apart in a truck.
Height and Weight Limits
Two limits control how tall you can stack. Max stack height is the full height, pallet included. Warehouse racking, truck doors, and air cargo holds all set this number. Max cargo height is just the boxes above the deck. The smaller limit wins. A common truck limit is about 1650 to 2000 mm total.
Weight matters too. A standard pallet holds roughly 1000 to 1500 kg. Going over that can crack the deck or crush the bottom boxes. Heavy boxes should go on the bottom layers.
Overhang
Overhang is when boxes stick out past the pallet edge. A small amount, up to about 50 mm per side, fits a few more boxes on. But overhanging boxes lose support and can lose up to a third of their stacking strength. Many carriers do not allow more than 152 mm (6 in), and some allow none at all.
Space Use
Two numbers show how well you filled the pallet. Area use is how much of the deck one layer covers. Packing efficiency is the box volume divided by the whole loaded space. Above 80% is good. Low numbers mean you are paying to ship air, and a different box size or pattern may fix it.