Pallet Load Calculator

Method and assumptions

This calculator compares two simple upright carton orientations. It does not create interlocking patterns or verify compression strength, overhang or transport regulations.

Worked scenario

Enter pallet footprint, maximum loaded height, payload and packed-carton dimensions and weight. Compare both upright carton orientations. Use the estimated cartons per layer and layers as a screening result, then reduce it for interlocking, edge protection, overhang limits and handling clearance.

How to interpret the result

The highest geometric count may fail compression, stability or axle-load requirements. Payload can become the binding constraint before height. A real pallet plan should be reviewed with packaging and warehouse teams and validated with a physical trial for high-volume products.

Input reference

Pallet length (cm)

Example default: 120

Pallet width (cm)

Example default: 100

Maximum loaded height (cm)

Example default: 180

Empty pallet height (cm)

Example default: 15

Maximum payload (kg)

Example default: 1000

Carton length (cm)

Example default: 40

Carton width (cm)

Example default: 30

Carton height (cm)

Example default: 25

Carton gross weight (kg)

Example default: 12

Common mistakes

• Ignoring pallet height and weight in the loaded limit.
• Selecting the largest count without stability review.
• Using nominal carton dimensions before production packing.

Before using the result

1. Confirm external dimensions and gross carton weight.
2. Check both dimension and payload constraints.
3. Approve the pattern with a physical loading trial.

Questions to check before deciding