Check both 90-degree orientations
A carton that wastes space in one direction can fit cleanly when rotated. More advanced interlocking layouts need stability and crush-strength checks.
Use the tighter layer limit
Calculate how many layers fit under the loaded-height cap and how many fit under the gross-mass cap. The smaller value governs.
Worked example: 48 × 40 inch pallet
A 16 × 12 inch carton footprint fits 3 by 3 in one regular orientation, producing 9 cartons per layer. Rotating every carton produces 4 by 2, or 8, so the first orientation is the better regular grid.
With a 6-inch pallet, 10-inch cartons and a 58-inch loaded-height cap, five carton layers fit. If the mass limit also allows five layers, the regular-grid planning result is 45 cartons.
Move from capacity to a safe load
The mathematical count is a starting point. Confirm carton compression, pallet rating, load stability, centre of gravity, wrapping and the receiving facility’s limits before using the result operationally.
- Deck fit controls cartons per layer
- Height and gross weight control the layer count
- The smaller allowable layer count governs
- A physical load test validates the plan
Questions this guide should answer
Does the calculator test interlocking pallet patterns?
No. It evaluates standard 90-degree regular layouts. Interlocking or mixed-row patterns need additional stability and structural checks.
What limits the number of pallet layers?
Calculate the layer allowance for loaded height and for gross weight. The smaller allowance is the planning limit.