Calculator inputs
Plotly graph
This graph compares pallet capacity, shipment totals, and trailer loading positions from your current result.
Example data table
| Scenario | Pallet size | Carton size | Total cartons | Cartons per pallet | Pallets required |
|---|---|---|---|---|---|
| Retail replenishment | 120 × 100 × 15 cm | 40 × 30 × 25 cm | 240 | 36 | 7 |
| Food distribution | 120 × 100 × 15 cm | 50 × 40 × 20 cm | 180 | 24 | 8 |
| Pharma cartons | 120 × 80 × 14 cm | 30 × 20 × 18 cm | 320 | 80 | 4 |
| Ecommerce mixed case | 48 × 40 × 6 in | 16 × 12 × 10 in | 150 | 18 | 9 |
Use the example rows as planning references only. Real outcomes change with height limits, overhang allowances, and pallet weight rules.
Formula used
Cartons per layer = max of aligned layout and turned layout.
Aligned layout = floor(usable pallet length ÷ carton length) × floor(usable pallet width ÷ carton width).
Turned layout = floor(usable pallet length ÷ carton width) × floor(usable pallet width ÷ carton length).
Layers by height = floor((maximum loaded height − pallet height) ÷ carton height).
Cartons by weight = floor((maximum pallet gross weight − pallet tare) ÷ carton weight).
Cartons per pallet = minimum of height capacity and weight capacity.
Pallets required = ceiling(total cartons ÷ cartons per pallet).
The calculator uses conservative rectangular packing. It does not model pinwheel, interlock, or irregular case patterns, so real warehouse fits may be slightly higher.
How to use this calculator
- Choose your working units for dimensions and weights.
- Enter pallet dimensions, carton dimensions, and carton weight.
- Add the total carton count for the shipment.
- Set the allowed overhang, maximum stack height, and gross pallet weight limit.
- Enter pallet tare weight so the gross load stays realistic.
- Select best fit, aligned, or turned carton orientation.
- Optionally enter trailer dimensions to estimate pallet positions and trailer count.
- Submit the form and review pallets required, cube, weight, utilization, and trailer planning metrics above the form.
FAQs
1) What does a shipping pallet calculator estimate?
It estimates how many cartons fit per layer, how many layers fit by height, final cartons per pallet, total pallets required, palletized cube, shipment weight, and optional trailer positions.
2) Why does carton orientation matter?
Turning a carton can change how many cases fit across the pallet footprint. Even simple rotation can improve layer capacity, reduce pallet count, and raise floor utilization.
3) What is the difference between carton cube and palletized cube?
Carton cube measures only the cartons themselves. Palletized cube includes pallet footprint and stacked height, which better reflects freight, warehouse space, and trailer planning.
4) Why can weight limit reduce cartons per pallet?
Even when more cartons fit physically, the pallet may exceed safe gross weight. The calculator caps cartons per pallet using the lower result between height capacity and weight capacity.
5) Should overhang always be used?
Not always. Small overhang can improve fit, but too much can reduce load stability, increase product damage risk, and conflict with warehouse or carrier handling rules.
6) Does this calculator support mixed SKU pallets?
This version is designed for one carton size at a time. For mixed SKUs, run separate scenarios or build a weighted planning model by grouping similar carton sizes.
7) How accurate is the trailer position estimate?
It is a planning estimate based on trailer floor length and width. Real loading can vary because of wheel wells, loading pattern, aisle needs, and carrier-specific restrictions.
8) Can I use this for warehouse storage planning?
Yes. The storage footprint and palletized cube outputs help estimate staging space, reserve locations, and short-term floor area requirements for inbound or outbound shipments.