Whether you ship goods by truck or store them in a warehouse, the number of boxes per pallet sets your freight cost per unit. A few millimeters of box size can mean a whole extra row. This calculator tries two simple patterns, all boxes the same way and a mixed block with the remaining strip turned, then stacks as many layers as the height and weight limits allow.
Standard pallets
| Pallet | Size | Typical use |
|---|---|---|
| GMA (North America) | 48 × 40 in | grocery and general freight in the United States |
| EUR / EPAL | 120 × 80 cm (47.2 × 31.5 in) | Europe, fits 33 in a truck |
| ISO / industrial | 120 × 100 cm (47.2 × 39.4 in) | Europe and Asia |
| Australian | 1165 × 1165 mm | Australia |
A GMA pallet is about 6 in high; a EUR pallet 144 mm. Truck and warehouse rules usually limit loads to about 60 to 72 in high overall, and the pallet to around 2,500 lb (1,000 to 1,500 kg) of goods.
How the count works
- Per layer: the calculator compares placing every box lengthwise, every box crosswise, and a block of one orientation with the leftover strip filled by boxes turned the other way. It keeps the best.
- Layers: floor((maximum height - pallet height) / box height).
- Weight check: if the boxes are heavy, the weight limit may stop the stack before the height limit.
Example
On a 48 × 40 in pallet, 16 × 12 × 10 in boxes fit 3 × 3 = 9 per layer. With a 60 in limit and a 6 in pallet, 54 in of headroom gives 5 layers: 45 boxes weighing 1,125 lb at 25 lb each.
Tips for better pallets
- Avoid overhang: boxes hanging over the edge lose up to a third of their stacking strength and get crushed.
- Column or interlock: stacking boxes directly on top of each other (columns) keeps their full strength; interlocking layers is more stable but weaker. Use columns with stretch wrap for heavy cartons.
- Use the footprint: a footprint use under about 85% often means a different box size would ship cheaper.
- Heavy at the bottom and labels facing out.
Limits
Real pallet software tests many more patterns, including pinwheels and mixed layers. The count here is a quick, reliable lower bound. Check the strength of your cartons (ECT or BCT rating) before stacking them high.