Freight & Logistics
Cartons per Pallet Calculator
Compare carton orientations on a pallet deck, then apply loaded-height and payload limits. See the selected top view, per-layer count and the remainder for a complete shipment.
Change any input to update the calculation. Unit changes preserve the physical quantity.
Inputs
Enter 0 to omit the shipment estimate.
Calculated locally in your browser. No sign-up or input upload.
Results
Cartons per pallet
40Cartons per layer · TI
8Layers used · HI
5Full layers allowed by height
5Loaded height at capacity
1,394 mm54.882 inCargo payload at capacity
400 kg881.849 lbGross pallet weight at capacity
425 kg936.965 lbDeck utilization per full layer
100 %Pallets required
3Cartons on final partial pallet
20Unused carton spaces across shipment
20Unassigned cartons
0Calculation breakdown
- Selected layout
- Rotated grid · no overhang
- Uppermost layer
- 8 cartons (full layer)
- Shipment assignment
- 2 full pallets + 1 partial pallet with 20 cartons. Unassigned cartons: 0.
Assumptions & checks
No overhang is allowed. Results optimize geometric fit among tested layouts and do not validate carton compression, load stability or pallet structural capacity.
Rotation is in-plane only; carton height stays upright. Payload is a user-entered limit. A weight-limited pallet may have a partial top layer.
Formula
Best count among pure grids and simple two-block splits. Cartons rotate only in the deck plane; this is not an exhaustive packing or stability solver.
Worked example
Using the default values shown in the calculator, the same formula gives the following result. This is a quick sanity check for the calculation, not a design recommendation.
Inputs
- Carton length
- 400 mm
- Carton width
- 300 mm
- Carton height
- 250 mm
- Carton weight
- 10 kg
- Pallet deck length
- 1200 mm
- Pallet deck width
- 800 mm
- Pallet height
- 144 mm
- Maximum loaded height (including pallet)
- 1500 mm
- Maximum cargo payload (excluding tare)
- 1000 kg
- Pallet tare
- 25 kg
- Shipment carton quantity (optional)
- 100
- Carton rotation
- Allow 90° in-plane rotation
Result
- Cartons per pallet
- 40
- Cartons per layer · TI
- 8
- Layers used · HI
- 5
- Full layers allowed by height
- 5
- Loaded height at capacity
- 1,394 mm
- Cargo payload at capacity
- 400 kg
- Gross pallet weight at capacity
- 425 kg
- Deck utilization per full layer
- 100 %
- Pallets required
- 3
- Cartons on final partial pallet
- 20
- Unused carton spaces across shipment
- 20
- Unassigned cartons
- 0
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Frequently asked questions
What are TI and HI?
TI is cartons per full layer in the selected layout. HI is the number of occupied layers at the calculated capacity. Payload limits can leave the uppermost layer partly filled.
Is this a guaranteed optimal or safe load plan?
No. It tests grids and two-block splits with no overhang, not every possible layout. Check packaging compression, restraint, stability, handling and actual pallet capacity before loading.
What does the unused-carton result mean?
All entered cartons are assigned to the reported number of pallets. The remainder is cartons on the last partial pallet; unused capacity is the number of empty carton spaces across those pallets.
Reference data & method sources
- EPAL Euro pallet dimensions
1200 × 800 × 144 mm, approximately 25 kg tare. This preset does not certify your pallet or load.