Pallet Calculator
Determine how many cartons fit onto standard US GMA, Euro, or custom pallets. Calculates mixed-row layer patterns (TI), layer counts (HI), maximum loaded heights, and weight constraints.
Pallet packing result
96 boxes/pallet
1 pallets
View detailsCarton & Pallet Setup
Enter outer carton dimensions, box weight, and pallet specifications.
Carton Dimensions & Weight
Pallet Specification
Pallet Stacking Optimization
1 pallet needed to transport 96 cartons. Footprint deck coverage: 100%.
- Total pallets required
- 1 pallet (for 96 boxes)
- Loaded pallet height
- 65" (6 layers)
- Cargo weight per pallet
- 1920 lb (Gross: 1970 lb)
- Deck surface utilization
- 100% (16 on deck)
Pallet Layer Pattern (Top View)16 boxes / layer
4 × 4 uniform layout • Utilization: 100%
Next Step: Plan Transportation & Freight Rates
Understanding TI × HI and pallet layer geometry
Warehouse and logistics teams express pallet packing configurations using TI × HI:
- TI (Tier): Number of cartons placed on a single horizontal layer of the pallet deck.
- HI (High): Number of layers stacked vertically from the pallet deckboard to the top.
Boxes per Pallet = TI (Boxes / Layer) × HI (Layers Count)
Total Height = Pallet Base Height (~5") + (HI × Carton Height)
Our layout engine tests both uniform grid alignments and mixed-orientation pinwheel rows to maximize footprint coverage without allowing overhang.
Height and weight constraints in palletization
Maximum pallet capacity is dictated by the lesser of geometric volume and transport weight limits:
- Rack & Trailer Clearances: Standard dry vans accommodate pallet heights up to 90–96", but common warehouse pallet rack beams and LTL double-stacking rules often limit total loaded height to 48"–65".
- Pallet Structural Limits: Standard Grade A GMA wooden pallets are typically rated for 2,500 lb dynamic payload. When shipping dense liquids or metal fasteners, the weight limit will be reached before physical space is filled.
Workflow Integration
Once you find the ideal pallet layout, click "Apply Pallets to Workspace" to immediately transfer the resulting pallets to the Linear Feet and Freight Class tools.
Packaging & Measuring SOP
Need guidance on stretch wrapping, column vs. interlocking strength, and eliminating overhang? Read our Pallet Shipping Guide →
Frequently asked questions
Common operational questions about carton layout, pallet presets, and height rules.
What is the standard US pallet size?
The Grocery Manufacturers Association (GMA) standard pallet measures 48 inches long by 40 inches wide, with a standard wooden base height of approximately 4.75–5.0 inches.
Why is pallet overhang generally discouraged?
When cartons extend beyond the perimeter of the pallet deck, edge compression resistance drops by up to 30%, making cartons vulnerable to puncture by adjacent pallets and forklift masts during transit.
How does the 3D model help with pallet planning?
The interactive 3D WebGL viewer lets you inspect all stacked layers from any angle, ensuring warehouse teams and packaging engineers can visually confirm box column stability before stretch wrapping.
Can I calculate partial pallets?
Yes. Enter your total production quantity (e.g. 275 cartons). The tool will output the exact staging plan: how many full pallets are needed and the exact carton count and height of the partial top-off pallet.