Build better pallets with smart case placement rules. See layers, weights, and fill percentage instantly. Ship safer loads while cutting space and costs overall.
Meta Plan stable pallets fast with accurate stacking math. Compare rotations, height, and weight limits. Reduce air, damage, and rework across shipments today easily.
| Scenario | Pallet (L×W×H) | Max height | Max gross | Case (L×W×H) | Case wt | Gaps / Clearance | Rotation |
|---|---|---|---|---|---|---|---|
| Euro pallet, general cartons | 120×80×14.4 cm | 160 cm | 800 kg | 40×30×25 cm | 10 kg | 0 / 0 cm | Allowed |
| UK pallet, fragile goods | 120×100×15 cm | 140 cm | 600 kg | 50×40×20 cm | 8 kg | 1 cm gaps • 1 cm clearance | Not allowed |
| US pallet, e-commerce cases | 48×40×6 in | 60 in | 1500 lb | 16×12×10 in | 22 lb | 0 / 0 in | Allowed |
Use examples as starting points, then tune constraints for your lane, carrier, and warehouse rules.
Usable pallet footprint considers edge clearance and overhang:
Effective case pitch includes optional gaps:
Cases per layer for a chosen orientation:
If rotation is allowed, the calculator also tries the 90° rotated case footprint and keeps the better result.
Height limit layers:
Weight limit cases:
Total cases is the tightest constraint:
Utilization:
Consistent pallet builds reduce damage, rework, and trailer cube loss. This calculator transforms pallet size, carton dimensions, and lane rules into a verified pattern that supervisors can standardize across shifts and sites.
Usable deck space is the pallet footprint adjusted for edge clearance and permitted overhang. Cases per layer are floor divisions of usable length and width by case pitch, where pitch equals case dimension plus any gap. If rotation is allowed, the tool evaluates both orientations and keeps the higher layer count.
Available stack height equals maximum total height minus pallet height. Layers by height are the floor of available stack height divided by case height. You may also set a maximum layers cap to reflect crush strength, stretch-wrap stability, or customer handling requirements.
Available payload equals maximum gross weight minus pallet tare. Cases by weight are the floor of available payload divided by case weight. Total cases are set by the tighter of height capacity and weight capacity, ensuring the resulting gross weight stays within the limit for carriers and racking.
Footprint fill measures deck utilization as case area per layer divided by pallet area. Volume fill measures cube utilization as total case volume divided by the available pallet volume under the height limit. Higher fill generally lowers cost per unit shipped, but very high fill can reduce airflow or increase handling effort.
The results summary shows cases per layer, layers used, top-layer remainder, load height, and weights in your selected units. The Plotly chart highlights which constraint is binding by comparing height-limited cases, weight-limited cases, and the final total. Export the CSV to attach to WMS task notes, and use the PDF as a pick-face build sheet.
For planning meetings, save a few scenarios with different gaps, clearances, or carton sizes and compare fill percentages side by side. A small reduction in case height can unlock an extra layer, while a lighter case may shift the binding constraint from weight to height. These comparisons support packaging redesign, lane optimization, and safer manual handling decisions in daily operations.
It is the maximum number of cases that fit on one pallet layer, based on usable deck space, gaps, clearance, and optional rotation. It drives total capacity when combined with layers.
Turning cases 90 degrees changes the pitch along length and width. If one dimension aligns better with the pallet footprint, the count along each axis can increase, raising cases per layer.
The tool computes a height-limited capacity and a weight-limited capacity. The final total is the smaller value, preventing stacks that exceed the permitted height or the gross weight limit.
Footprint fill evaluates deck coverage on a single layer. Cube fill evaluates volume usage under the height limit. Both help compare packaging options, but cube fill reflects vertical efficiency.
Use gaps to allow stretch wrap, corner boards, or airflow. Use clearance to keep cartons inside the pallet perimeter for handling and to reduce edge crush. Follow your SOP and lane rules.
If weight becomes the binding constraint, the total cases may not complete the final layer. The calculator reports the remainder so teams know the exact top-layer count during building.
Important Note: All the Calculators listed in this site are for educational purpose only and we do not guarentee the accuracy of results. Please do consult with other sources as well.