Input Parameters
Example Data Table
| Scenario | Warehouse (m) | Bay / Depth (m) | Aisle (m) | Levels | Gross Positions | Net Positions (90%) |
|---|---|---|---|---|---|---|
| Standard selective | 60 × 30 | 2.70 / 1.10 | 3.20 | Auto | ~1,728 | ~1,555 |
| Narrower building | 50 × 18 | 2.70 / 1.10 | 3.00 | 4 | ~640 | ~576 |
| Single-row layout | 70 × 24 | 2.70 / 1.10 | 3.50 | 5 | ~1,300 | ~1,170 |
Example values are illustrative. Use the calculator for precise counts.
Formula Used
- Usable length:
Lu = L − Lcross - Bays per row:
B = ⌊ Lu / Lbay ⌋ - Pallets per bay (Auto):
P = max(1, ⌊ (Lbay − Cbeam) / Wpallet ⌋) - Levels (Auto):
N = max(1, ⌊ (H − Ctop) / (Hpallet + Cvert) ⌋) - Rows across width: computed by fitting rack depth blocks plus aisles into
W. - Gross positions:
G = Rows × B × P × N - Net positions:
Net = ⌊ G × (Utilization% / 100) ⌋
How to Use This Calculator
- Enter your warehouse length, width, and clear height.
- Provide pallet width and pallet height for vertical planning.
- Set rack bay length, rack depth, and aisle width.
- Choose layout type: back-to-back for density, single rows for access.
- Pick Auto levels for quick checks, or Manual for known designs.
- Adjust utilization factor to reflect columns and operational constraints.
- Click Calculate to view net and gross positions above the form.
- Use Download buttons to export results as CSV or PDF.
For final design, confirm with a rack supplier and local safety codes.
Pallet Position Planning Notes
1) Why pallet positions matter
A pallet position is one pallet stored in one location at one time. Estimating positions early helps right-size the warehouse footprint, rack system, and material-handling plan. When capacity is too low, overflow storage increases travel and damage risk. When it is too high, unused cubic volume becomes expensive space.
2) Inputs that drive capacity
The calculator converts clear storage dimensions into a grid of pallets using pallet length/width, aisle width, and rack levels. For example, a 40 m by 24 m clear storage area with 1.20 m by 1.00 m pallets, 3.2 m aisles, and 4 levels provides a realistic baseline. Changing aisle width by 0.5 m can reduce usable floor rows noticeably. Reach trucks often work with 2.7–3.0 m aisles, while counterbalance trucks may need 3.5–4.0 m, depending on turning and load overhang.
3) Clear height and level count
Level count depends on clear height, beam depth, pallet load height, and top clearance. A 9.0 m clear height with 1.60 m average loaded pallet height and 0.50 m top clearance can often fit about 5 storage levels, depending on the rack and lift-truck limits. Use conservative values where load heights vary.
4) Utilization and real-world obstructions
Columns, fire lanes, dock doors, and staging zones reduce the theoretical maximum. The utilization factor adjusts for these constraints. Typical planning values range from 0.75 to 0.90. If you are including picking faces, battery-charging areas, or wide turning radii, use the lower end.
5) Turning results into layout decisions
Compare net positions (usable storage) to required positions derived from inventory profiles and service levels. If net positions are short, consider narrower aisles, higher levels, or an alternative rack type. If net positions exceed demand, allocate space to inbound/outbound staging or future growth. Always confirm egress paths, fire separation, and inspection access before finalizing the layout.
FAQs
1) What is a “pallet position”?
A pallet position is one pallet stored in one dedicated slot, such as one bay location on a rack level.
2) Why does aisle width affect positions so much?
Wider aisles consume floor area that could otherwise hold rack rows, reducing the number of pallet footprints that fit.
3) How should I choose the utilization factor?
Start with 0.85 for clean layouts. Reduce to 0.75–0.80 if you expect columns, fire lanes, staging, or frequent congestion.
4) Does the calculator include rack upright and beam thickness?
It uses simplified clear dimensions. For detailed design, subtract rack clearances and consult supplier bay spacing data.
5) What if pallet sizes vary?
Use the dominant pallet size for planning, or run multiple scenarios and design zones by pallet class.
6) How do I estimate pallet load height?
Use the typical stacked height including pallet, product, and overhang allowance. If heights vary, use a higher percentile value.
7) Can I use this for block stacking?
Yes, set rack levels to 1 and treat aisles as block-stacking lanes, but verify stability, fire rules, and access needs.