How many boxes fit on a pallet?

The short answer

For identical rectangular cartons, calculate the strongest two-dimensional pattern on the pallet footprint, multiply by the number of usable layers, then apply payload and requested-quantity limits. Volume alone can overstate capacity because unused gaps and box orientation matter.

Calculation sequence

1. Measure pallet length and width.
2. Measure the outside length, width and height of one packed carton.
3. Find the best boxes-per-layer pattern using allowed rotations.
4. Calculate usable layers from the maximum total pallet height minus pallet base height.
5. Check payload: floor(allowed cargo weight ÷ box weight).
6. The final capacity is the minimum of geometric capacity, payload capacity and requested quantity.

Worked example

A 1200 × 800 mm EUR pallet with 400 × 300 × 250 mm cartons can fit 8 cartons per layer in a strong rectangular pattern. With a 1800 mm total-height limit and a 144 mm pallet base, six layers fit, giving 48 cartons before the payload limit is applied.

Why two calculators can disagree

Different tools may assume overhang, ignore payload, use only aligned rows, allow different rotations or use different pallet base heights. PackMize exposes the dimensions and constraints so the result can be reproduced.

Frequently asked questions

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