Cases per Pallet Calculator
How many cartons fit on a pallet: Ti × Hi from carton and pallet size with lengthwise, crosswise and mixed two-block layer patterns, standard pallet presets, overhang, height, weight and layer limits, loaded height and gross weight, cube use, pallets for a shipment and pallets per container or trailer.
How it works
Lengthwise = ⌊PL/CL⌋ × ⌊PW/CW⌋ · crosswise = ⌊PL/CW⌋ × ⌊PW/CL⌋ · mixed = best split of the deck into a lengthwise block and a crosswise block · Ti = best of these · Hi = min(⌊(H_max − deck)/CH⌋, ⌊W_max/(Ti × case weight)⌋, layer limit) · cases = Ti × Hi
A pallet build is described as Ti × Hi: Ti (tie) is cases per layer and Hi (high) the number of layers. Ti is set by the deck footprint: the calculator tries every case lengthwise, every case crosswise, and mixed two-block patterns where some rows are turned 90° to use the leftover strip — often one or two cases more per layer. Pick a single orientation if the pallet is built by hand and speed matters, or allow overhang if your customer accepts it. Hi is set by whichever bites first: the maximum loaded height (including the pallet deck) allowed by the trailer, rack or retailer, the weight the pallet, forklift or floor can carry (with or without the pallet itself), or the number of layers the bottom carton can bear. Choose a standard pallet size or enter your own, and under More options let cases lie on their side, enter a shipment quantity to get the number of pallets, or check how many pallets fit in a 20 or 40-foot container or a 53-foot trailer and whether they can be double-stacked. Retailer guides typically cap pallets at 48–72 inches and about 2,000–2,500 lb. Column stacking (cases directly above each other) is roughly a third stronger than interlocking; interlock only the top layers or use slip sheets if cartons are strong.
Worked example
16 × 12 × 10 in cases of 25 lb on a 48 × 40 GMA pallet with a 5.5 in deck and a 60 in / 2,500 lb limit: lengthwise gives 3 × 3 = 9 per layer, but two rows of 3 lengthwise (24 in deep) plus one row of 4 crosswise (16 in deep) fill the full 40 in for 10 per layer. (60 − 5.5) ÷ 10 = 5.45, so 5 layers fit under the height limit — Ti × Hi = 10 × 5 = 50 cases, 1,250 lb of product (1,290 lb with a 40 lb pallet) and 55.5 in tall.
Frequently asked questions
What does Ti × Hi mean?
Ti (tie) is the number of cases in one layer and Hi (high) is the number of layers. A 10 × 5 pallet holds 50 cases. Warehouses and retailers specify pallets this way so every pallet of a product is built the same.
Should I interlock layers?
Interlocking (rotating alternate layers) stabilises the load but reduces compression strength by about a third because corners no longer line up. Column-stack and use corner boards plus stretch wrap when cartons are heavy or humid.
Why does the mixed pattern fit more cases?
When the pallet width is not an exact multiple of the case width, a single orientation leaves a strip empty. Turning one or more rows 90° can use that strip: 16 × 12 in cases on a 48 × 40 pallet fit 9 one way but 10 with two rows lengthwise and one row crosswise.
Is the weight limit with or without the pallet?
It depends on who sets it. Carrier and 3PL limits are usually gross (including the pallet), while some retailer specs are for product only. Turn on “Weight limit includes the pallet” under More options for a gross limit.
What about mixed-SKU pallets?
Put the heaviest, strongest cases at the bottom and keep the total height under the retailer limit; this tool assumes one case size.
Related calculators
Planning estimate. Carrier tariffs, NMFC classifications, axle limits and port charges vary — confirm with your carrier, 3PL or the applicable regulation before committing.