Pallet Calculator — Boxes per Pallet & TI-HI
Find boxes per layer, total pallet capacity, utilization, height and weight from actual rectangular layouts.
How many boxes fit on a Euro pallet?
With a 1200 × 800 mm pallet and 400 × 300 × 250 mm cartons, rotation permits 8 boxes per layer. At a maximum total height of 1800 mm and a 144 mm pallet base, 6 layers fit: 48 boxes. With 8 kg per box, a 1500 kg payload limit and 25 kg pallet tare, the gross weight is 409 kg. Total height is 1644 mm.
Planning a real order with several SKUs?
Keep this single-SKU calculator free. For an actual shipment, import the order, optimize mixed pallets and generate a professional load plan.
How the pallet calculator works
PackMize converts all dimensions to a common internal unit, tests aligned, rotated and mixed rectangular layer layouts, then applies the selected total-height and payload limits. The pallet preset value is treated as payload capacity; pallet tare is added only when reporting gross pallet weight. It does not estimate capacity by volume alone.
Assumptions and limitations
The engine assumes rigid rectangular boxes on a rectangular pallet. It does not model carton deformation, load stability, overhang, inter-layer compression, strap placement, center of gravity or transport regulations. A high utilization number is not a safety certification.
Preset assumptions and sources
The EUR / EPAL 1 preset follows the published EPAL dimensions and planning load. The 48 × 40 in preset uses the widely documented North American footprint, while tare and payload remain planning defaults unless you replace them with the actual pallet rating. See Standards, assumptions & data sources.
Example
For a 1200 × 800 mm EUR pallet and 400 × 300 mm cartons, multiple orientations are tested. The optimizer evaluates several deterministic placement strategies. When the selected layer reaches the area-based mathematical upper bound and the final capacity also reaches the active height/payload/quantity bound, PackMize labels the result PROVEN OPTIMAL; otherwise it reports BEST SOLUTION FOUND.
Frequently asked questions
How does the pallet calculator decide how many boxes fit?
It tests aligned, rotated and mixed rectangular layer layouts, then applies stack-height and weight limits.
Does it use pallet volume only?
No. PackMize places rectangular box footprints on the pallet base. Volume alone can overstate capacity.
Is the result guaranteed to be the global optimum?
PackMize shows PROVEN OPTIMAL only when the layout reaches a mathematical upper bound for the modeled constraints. Otherwise it reports BEST SOLUTION FOUND.
What does TI-HI mean?
TI is the number of boxes per layer. HI is the number of layers. TI multiplied by HI gives a full-layer pallet count, before quantity or payload reduces the final load.
Can I use a 48 by 40 inch pallet?
Yes. Choose the US GMA pallet preset or enter a custom footprint, select inches, and enter the actual carton dimensions, height and payload limits.