Enter a carton size and a pallet. This works out how many cartons fit on each layer, how many layers fit under your height limit, and draws the layer from above.
A straight grid is not always the best pattern. Turning part of the layer often fits another carton or two, and that adds up across every layer.
Cartons stay upright and never overhang the deck. Overhang crushes carton edges, and a load that sticks out measures bigger, which can push freight into a higher class.
The calculator tries a straight grid both ways round. Then it tries splitting the deck into two blocks, one with cartons facing one way and one with them turned 90°, at every split point along both sides. It keeps whichever pattern fits the most cartons.
A 16 × 12 in carton on a 48 × 40 pallet fits 9 in a straight grid. Two rows of 3 plus a turned row of 4 fits 10. Over 6 layers that is 6 more cartons on the same pallet.
Take your height limit, subtract the height of the pallet deck, and divide by the carton height. Round down. A 72 in limit on a 6 in deck leaves 66 in, which is 6 layers of 10 in cartons.
(Height limit − deck height) ÷ carton height = layers, rounded down
| Size | Where it is used |
|---|---|
| 48 × 40 in | The most common pallet in the US, often called the GMA pallet. The usual size for retail and Amazon |
| 48 × 48 in | Square. Used for drums and bulk bags |
| 42 × 42 in | Square. Used for telecom and paint |
Column stacking, with every carton directly above the one below, keeps the most strength in the carton walls. Interlocking, where each layer turns, ties the load together better. Put heavy cartons at the bottom, keep the load inside the edges of the deck, and wrap it tight to the pallet.
BoxHero builds wholesale and Amazon FBA pallets out of Brooklyn. Add carton weight and a weight limit with the max cartons per pallet calculator, or check the class with the freight class calculator.
No. Overhang loses the support of the deck and crushes carton edges. It also makes the load measure bigger, which can raise the freight class.
Because a mixed pattern often fits more than a straight grid. The diagram shows turned cartons in orange.
The one your carrier, warehouse or customer sets. Amazon FBA pallets are commonly published at 72 in including the pallet.
No. This plans the space. The max cartons per pallet calculator adds carton weight and a weight limit and tells you which one runs out first.
Tell us your orders a month and units per order. You see a per-order price before you commit to anything.
Your brand's warehouse partner in Brooklyn. We do everything outside of selling the products you own.