How to calculate boxes per pallet
Build a TI/HI estimate from layer geometry, total loaded height, and gross weight, then separate geometric fit from safe stacking.
Have your measurements ready? Put the method to work.
Pallet CalculatorDefine the pallet and carton before stacking
Use the usable deck dimensions and the carton's external dimensions. Record empty pallet height and weight separately from the carton load. A maximum loaded height includes the pallet itself, while a maximum gross weight includes both pallet and cartons.
Decide which rotations are physically acceptable. Turning a carton within a layer is different from laying it on its side. Product orientation markings, liquid containers, fragile inserts, and carton strength may rule out some geometrically attractive positions.
TI describes a layer; HI describes the stack
TI is cartons per layer. HI is the number of layers. For a uniform layout, try floor(pallet length ÷ carton length) × floor(pallet width ÷ carton width), then try a 90-degree rotation. Mixed rows can sometimes fit more cartons than either uniform grid.
PackCalcs compares supported strip arrangements rather than proving every possible two-dimensional packing pattern. Its drawing lets you inspect the candidate layout. Do not call the result a mathematical maximum unless a separate proof establishes one.
Worked example: height and weight limits
A 120 × 80 cm deck fits six 40 × 40 cm cartons per layer. Each carton is 20 cm tall and weighs 10 kg. With a 15 cm tall, 25 kg empty pallet and a 115 cm loaded-height limit, available carton height is 100 cm: five layers, or 30 cartons.
The full load is 30 × 10 + 25 = 325 kg gross. If the gross limit is only 285 kg, the carton allowance is 260 kg and at most 26 cartons are permitted by weight. That means four full layers plus two cartons on top, subject to a separate stability review. A partial top layer should never be mistaken for five full layers.
Utilization is a geometric measure
Six 40 × 40 cm cartons occupy 9,600 cm², the same as a 120 × 80 cm deck, so the layer has 100% area utilization. That describes the footprint; it says nothing about whether the bottom cartons can carry the stack.
Deck gaps, moisture, carton compression, interlocking versus column stacking, center of gravity, restraint, and handling influence a real pallet. A high utilization percentage cannot certify these properties.
Use the plan to prepare a practical check
Print the arrangement with the carton dimensions, permitted rotation, layer count, partial-layer quantity, total height, and gross weight. Confirm that the actual pallet matches the entered size and is suitable for its intended handling environment.
Build and inspect a sample load before repeating it at scale. Then use the pallet wrap estimator for a material-use scenario and the container calculator for placement; both remain separate from load-safety validation.
Technical references
Service rules and equipment can change. Verify the specifications for your shipment.