A pallet packing calculator determines the maximum number of cartons that fit on a standard pallet by optimizing layer layout and rotation patterns. Enter carton dimensions, pallet size, and weight limits to see per-layer diagrams and total utilization percentage.
Carton & Pallet Specs
Packing Results
Layer Layout (Top-Down View)
Enter carton and pallet specs to see the layout.
Warehouse Packing Gear
An optimized pallet layout means nothing if your cartons collapse during transit. To ensure your pallet holds its shape during shipping, you must secure it properly. We strongly recommend using heavy-duty 80-gauge stretch wrap, which provides the puncture resistance and tension required to lock heavy cartons together. Furthermore, to prevent the stretch wrap from crushing the corners of your top layer cartons, always apply cardboard edge protectors along the vertical corners of your pallet before wrapping.
How to Optimize Pallet Packing
Shipping "air" is the most expensive mistake in logistics. When loading cartons onto a standard 48"x40" pallet, poor arrangement can leave wide gaps, reducing the number of units you can ship per pallet and drastically inflating your freight costs. The goal is to fill the cube you are paying for while staying inside your product height and pallet weight limits.
PalletPack searches the layer for you. It tries both floor rotations of the carton, and it also cuts the pallet into blocks that are each packed in their own rotation, which is how mixed-orientation layers are built. The height you enter stays the stack axis: most cartons carry a "this side up" restriction, so laying a carton on its side is never searched, and on a tall narrow carton doing that by hand can beat anything shown here. Nor can straight cuts reach a pinwheel, the interlocking pattern where four blocks rotate around a centre. Treat the cartons-per-layer figure as a floor that is known to be physically placeable, not as a proven maximum, and check it against your own pattern before you book the freight.
Every layout the tool reports is drawn in the layer diagram, so the count on the card is the count of cartons in the picture. If a stack breaks the height limit or the weight limit you entered, the tool reports zero rather than shipping the pallet anyway.
Frequently Asked Questions
What are standard pallet dimensions?
The most common US pallet (GMA standard) is 48" × 40" and supports up to 2,500 lbs dynamic load. The Euro pallet (EPAL/EUR) is 800mm × 1200mm (31.5" × 47.2"). Other sizes include 42×42" (paint/chemical), 48×48" (drums), and 48×45" (automotive). Always confirm the pallet spec with your warehouse or carrier.
How tall can you stack a pallet for shipping?
Standard maximum pallet height is 48" of product on top of a 6" pallet = 54" total. Some carriers accept up to 72" total for LTL freight. Enter product height only in this calculator: the pallet deck is not part of the figure, so subtract about 6" (15 cm) from any overall height your carrier quotes. Stack height also depends on container dimensions: a 53-foot trailer interior is 108" high, allowing double-stacking of 54" pallets. Always confirm with your carrier and consider product crush resistance.
Should I rotate cartons on a pallet for better packing?
Yes — rotating cartons (alternating 0° and 90° orientations between layers) creates interlocking layers that prevent shifting during transport. Rotated layouts sometimes fit 5-10% more cartons per layer than uniform orientation. However, some products have 'this side up' restrictions that prevent rotation.