Pallet Loading Optimiser
Calculate how many boxes fit on a standard pallet by layer, the number of layers within your height limit, and the overall pallet area utilisation.
Results
What is it?
Pallet loading optimisation calculates how many boxes can be stacked on a pallet within a maximum height constraint. The calculator uses a simple column-row approach (no rotation or interlocking) to provide a baseline count — real-world optimisation may squeeze out additional units through pattern stacking or alternating orientations. The standard EUR pallet is 120x80 cm; the US GMA pallet is approximately 122x102 cm.
How to use
Enter the pallet footprint, the maximum permitted stack height (including the pallet board itself), and the outer dimensions of your carton. The calculator subtracts the pallet board height, then divides the remaining clearance by box height to determine layer count. Area utilisation shows how efficiently the pallet footprint is used.
Example scenario
EUR pallet (120x80 cm), max height 180 cm, pallet board 15 cm, boxes 40x30x25 cm. Boxes per row = floor(120/40) = 3. Boxes per column = floor(80/30) = 2. Per layer = 6. Available height = 165 cm. Layers = floor(165/25) = 6. Total = 36 boxes. Area utilisation = (6 x 40 x 30) / (120 x 80) x 100 = 75%.
Pro tip
This calculator assumes all boxes face the same direction. In practice, interlocking patterns (rotating every other layer 90 degrees) increase stability and can occasionally fit more units. Also consider weight limits: standard EUR pallets are rated for 1,500 kg dynamic and 4,000 kg static — always check total pallet weight before shipping.