The calculation, without hidden assumptions
Plan an upright single-SKU pallet load using both carton footprint orientations and mixed row splits. The result checks both available stack height and gross pallet weight, then shows TI (cartons per layer), HI (loaded layers), pallet count and final-pallet quantity.
How to use this calculator
Choose Euro, 1200 × 1000, GMA 48 × 40, Asian 1100 × 1100, or a custom pallet footprint.
Enter the packed carton outside dimensions and gross carton weight; cartons remain upright but may rotate 90° on the deck.
Enter pallet deck height/tare, maximum total loaded height and maximum gross pallet weight.
Read TI-HI, capacity, coverage, limiting constraint and pallets required. Verify stability and real pallet/carrier limits before loading.
Where people use it
- •Estimate pallets required before booking warehouse or freight capacity.
- •Check whether pallet capacity is limited by height or gross weight.
- •Compare Euro and GMA footprints for the same carton.
- •Estimate the partial final pallet for a purchase order or production batch.
40 × 30 × 25 cm cartons on a Euro pallet
A 120 × 80 cm Euro footprint can fit 8 cartons per 40 × 30 cm layer in a simple upright pattern. With a 14.4 cm pallet deck and 170 cm total-height limit, six 25 cm carton layers fit by height; the gross-weight limit may reduce that count.
What the result does not assume
- •This is a planning estimator, not a structural palletization approval. It does not model carton crush strength, pallet strength, centre of gravity, interlocking, stretch wrap, straps or transport dynamics.
- •The solver searches practical upright row patterns and mixed 90° row splits; it does not claim a mathematically global optimum for every 2D rectangle-packing problem.
- •Maximum gross weight and loaded height must come from the actual pallet, warehouse, vehicle, carrier and applicable safety rules. No overhang is assumed.
Frequently asked questions
What do TI and HI mean?+
TI is cartons per layer on the pallet footprint. HI is the number of carton layers used vertically.
Does the calculator rotate cartons?+
Yes, it tests 90° rotation on the pallet deck and mixed row splits. It keeps carton height upright and does not turn cartons onto their sides.
Does pallet height count toward the maximum loaded height?+
Yes. The height calculation subtracts the entered pallet deck height before calculating carton layers.
Does the pallet weight limit include the pallet?+
Yes. The entered maximum gross weight is compared after subtracting the empty pallet tare.
Why can a real pallet fit differently?+
Special interlocking patterns, allowed overhang, carton deformation or more advanced packing can change the count. Conversely, stability and crush limits can reduce a theoretical geometric count.
Semantic next steps
Continue the calculation
These links move to a different input, formula or project stage rather than a keyword variation of this page.
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