Pallet Load Calculator
Work out how many cartons fit on a pallet in each orientation, how many pallets fill a container, and what percentage of the space and weight allowance you are actually using.
Last reviewed by the Radiatus Cloud team
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How many cases fit is a packing problem
Getting cartons onto a pallet efficiently is not a division sum. A carton can sit in six orientations, each producing a different number per layer, and the best answer often mixes rotations within a layer. Guessing wrongly costs real money: a pallet built two cases short per layer over ten layers is twenty cases of freight you paid to move as air, on every pallet, on every shipment.
Layer patterns and stack height
The number per layer comes from how the carton footprint divides into the pallet footprint. This calculator tests both orientations of the carton against both orientations of the pallet and reports the best simple block pattern for each, along with the overhang or unused edge. Stack height then follows from the usable height, which is the container or trailer inside height minus the pallet base, and often minus a further allowance if the load will be double stacked.
Weight usually runs out before space
A standard forty foot container holds a large volume but is limited by a payload weight that dense goods reach long before the space is full. The calculator reports both the volumetric fill and the weight utilisation so you can see which constraint binds. If weight binds, a taller stack achieves nothing; if space binds, a denser carton or a smaller box is where the saving is.
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Frequently Asked Questions
Which pallet size should I choose?
Depends on the market. The 1200 by 800 millimetre Euro pallet dominates in Europe, the 48 by 40 inch GMA pallet in North America, and 1100 by 1100 millimetre in much of Asia. Shipping the wrong pallet standard into a market means it does not fit the racking at the other end.
Does the calculator allow overhang?
It reports overhang rather than allowing it silently. Most carriers and warehouses require the load to stay within the pallet footprint, since overhanging cartons are crushed in transit and prevent the pallets from being placed side by side in a container.
Why is my container weight limited before it is full?
Because container payload is capped, typically around 26 to 28 tonnes for a forty foot unit, and road weight limits at either end are often lower still. Dense products hit that limit with the container half empty, which is normal and not a packing error.
Can cartons be mixed in orientation within a layer?
Yes, and pinwheel or brick patterns often beat a simple block layout by a case or two per layer. This tool reports the best block pattern, which is what a manual build reliably achieves; specialist palletisation software finds the mixed patterns.
What height should I use for the stack?
The usable internal height minus the pallet base, and minus a few centimetres of clearance. A standard forty foot container has about 2.39 metres inside; a high cube has about 2.69. If the load will be double stacked in a warehouse, halve the working height.
Privacy & Security
Everything runs in your browser; nothing is uploaded.
How to Use
Enter carton and pallet dimensions to see the best layer pattern and total units per pallet.
Disclaimer: This tool is provided "as is" without warranty of any kind. Results are for educational and utility purposes.
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