How the pallet calculator works
The calculator answers three questions: how many cartons fit in one layer, how many layers fit under your height limit, and whether the result stays under your maximum pallet weight.
1. Cartons per layer
It first tries the simple patterns — every carton facing the same way, lengthwise and then rotated 90°:
Per layer = floor(pallet length ÷ carton length) × floor(pallet width ÷ carton width)It then tests two-block (mixed) patterns, where part of the pallet holds cartons one way and the rest holds them rotated. Mixed patterns often fit one or two extra cartons per layer and interlock better, which makes the load more stable. The best count wins.
2. Layers
Layers = floor((max height − pallet height) ÷ carton height)Cartons are kept upright (the height you enter stays vertical), which is how most packaging is designed to bear load.
3. Weight check
If cartons × carton weight + pallet weight exceeds your maximum gross weight, the total is reduced to the heaviest load allowed and the result tells you it was limited by weight.
Worked example
Cartons of 40 × 30 × 25 cm weighing 12 kg on a EUR pallet (120 × 80 cm, 14.4 cm tall), with a 180 cm height limit and a 1,000 kg gross limit:
- Uniform patterns give 3 × 2 = 6 or 4 × 2 = 8 per layer, so 8 per layer (rotated, 30 cm side along the 120 cm length).
- Layers: (180 − 14.4) ÷ 25 = 6.6, so 6 layers.
- Total: 8 × 6 = 48 cartons, 576 kg of product, about 601 kg gross — under the limit.
Common pallet sizes
| Pallet | Size | Where used |
|---|---|---|
| EUR / EPAL 1 | 1200 × 800 mm | Europe; retail and road freight |
| Industrial (EUR 2 / ISO) | 1200 × 1000 mm | Europe, UK, Asia; heavier goods |
| GMA | 48 × 40 in (1219 × 1016 mm) | USA and Canada |
| Asia / square | 1100 × 1100 mm | Japan, Korea, wider Asia |
Typical height limits are 1.8–2.2 m for road freight and lower for many warehouses and racking systems, so check your customer’s receiving requirements.
Frequently asked questions
How many boxes fit on a Euro pallet?
It depends on the box size and the height limit. For example, 40 x 30 x 25 cm cartons fit 8 per layer and 6 layers under 1.8 m, giving 48 cartons. Enter your own carton size above to get an exact count.
Should cartons overhang the pallet?
Generally no. Overhang concentrates weight on unsupported carton edges and can reduce compression strength significantly. The overhang field is there for cases where your customer allows a small amount.
What is a mixed or pinwheel pallet pattern?
A pattern where some cartons are turned 90 degrees relative to others. It can fit more cartons per layer and, when alternated between layers, ties the stack together for stability.
What is the maximum weight on a pallet?
A standard EUR pallet has a dynamic load rating of about 1,500 kg, but carriers, racking and handling equipment often set lower limits, commonly around 1,000 kg. Always use the lowest limit that applies.
Does the calculator rotate cartons onto their side?
No. It keeps the carton height vertical because most cartons are designed to be stacked upright. If your product can be laid on its side, swap the dimensions and compare.