How many boxes fit on a pallet?

Start with the actual loading limits

For identical rectangular cartons, check the pallet footprint, maximum total loaded height, pallet base height, packed weight per carton and available payload. These constraints can each reduce the count.

The worked example uses a 120 × 80 cm EPAL Euro pallet with a 14.4 cm base and approximately 25 kg tare. EPAL publishes a 1,500 kg safe working load. We enter 1,525 kg gross to represent 1,500 kg cargo plus the 25 kg example pallet. The 160 cm total-height limit is an editable planning choice; it is not an EPAL allowance.

Cartons are 40 × 30 × 25 cm, weighing 10 kg each, with 100 to ship. They stay upright. This example adds no gap or overhang; actual operations may require more clearance.

Find a layer that fits

Try both floor rotations. Keeping the 40 cm edge along the 120 cm pallet side gives floor(120 ÷ 40) × floor(80 ÷ 30) = 3 × 2 = 6 cartons. Turning the footprint gives floor(120 ÷ 30) × floor(80 ÷ 40) = 4 × 2 = 8 cartons.

The planner also tries two rectangular floor sections with different rotations. It repeats one supported layer pattern upwards. This is a limited planning model; it does not solve every possible arrangement or mixed-SKU load.

Calculate the number of layers

Usable carton height = total loaded-height limit − pallet/base height

160 − 14.4 = 145.6 cm is available for cartons. Each layer is 25 cm high, so floor(145.6 ÷ 25) = 5 complete layers. Geometric capacity is 8 × 5 = 40 cartons.

The full example pallet is 139.4 cm high including its base. The remaining 20.6 cm cannot take another 25 cm layer. If total height is reduced to 130 cm, the supported capacity becomes 32 cartons.

Apply the payload limit

Payload = maximum gross weight − empty equipment weight

For this example, 1,525 − 25 = 1,500 kg payload. At 10 kg per carton the weight bound is 150 cartons, so geometry limits the load to 40.

If each carton instead weighs 50 kg, payload permits only 30 cartons. That is three full 8-carton layers plus 6 cartons on the next layer; the geometric 40-carton count cannot be used.

Plan full and partial pallets

At 40 cartons per pallet, ceil(100 ÷ 40) = 3 pallets. The first two carry 40 cartons each. The last carries 20: 8 + 8 + 4, using 3 layers and a loaded height of 89.4 cm.

A partial final layer changes the load, not the maximum supported capacity. Secure and support any partial layer appropriately; this tool does not verify restraint or stacking strength.

Why the volume ratio is not capacity

The usable rectangular envelope is 1.2 × 0.8 × 1.456 = 1.39776 m³. One carton is 0.03 m³. Dividing those volumes suggests an upper bound of 46 whole cartons, yet the supported upright layout holds 40.

The division ignores whether another complete carton fits in the remaining height and floor pattern. A CBM total is useful for describing cargo volume; it cannot replace a dimensional layout or payload check.

Check the plan before loading

Use the pallet and container planner with the actual equipment limits. Floor rotation is always available; allow cartons to rest on their sides only if the goods and packaging permit it. The planner adds no automatic handling gap and does not model gaps between cartons.

For a container, optional door limits conservatively constrain the entire loading envelope. The result does not model individual loading moves, mixed carton sizes, box compression, weight distribution or cargo securing. Confirm a usable physical plan before arranging transport.

Sources and scope

Official references checked 4 October 2026. Numerical tables are worked planning examples using the stated inputs; they are not carrier prices or loading certification.

• EPAL: Euro pallet specifications ↗

  1,200 × 800 × 144 mm footprint/base; approximately 25 kg tare; published 1,500 kg safe working load. The example's total-height limit is user-selected.

Read our calculation methods and limitations. To report an error or a changed official rule, contact Freight Layout.