Pallet load calculator form
Enter shipment data in millimeters and kilograms. The calculator will optimize a pallet pattern and estimate pallets, weight, height, and cube.
Example data table
Use this sample to test the calculator quickly.
| Field | Example value | Field | Example value |
|---|---|---|---|
| Pallet size | 1200 × 1000 mm | Empty pallet height | 150 mm |
| Pallet tare weight | 25 kg | Maximum stack height | 1600 mm |
| Maximum payload | 1000 kg | Maximum gross weight | 1025 kg |
| Carton size | 400 × 300 × 250 mm | Carton weight | 12 kg |
| Total cartons | 180 | Units per carton | 1 |
| Overhang | 0 mm each side | Void factor | 5% |
| Safety margin | 5% | Orientation mode | Auto |
| Typical result | 40 cartons per pallet | Typical pallet count | 5 pallets |
Formula used
Effective Length = Pallet Length + 2 × Overhang Length
Effective Width = Pallet Width + 2 × Overhang Width
Cases per Layer = floor(Effective Length ÷ Carton Length) × floor(Effective Width ÷ Carton Width)
In auto mode, the calculator also checks the rotated carton orientation and keeps the better pattern.
Adjusted Cases = floor(Raw Cases × (1 − Void Factor ÷ 100))
Safe Stack Limit = Maximum Stack Height × (1 − Safety Margin ÷ 100)
Loadable Height = Safe Stack Limit − Empty Pallet Height
Maximum Layers = floor(Loadable Height ÷ Carton Height)
Cartons by Height = Adjusted Cases × Maximum Layers
Payload from Gross Limit = Maximum Gross Weight − Pallet Tare Weight
Usable Payload Limit = min(Maximum Payload, Payload from Gross Limit)
Safe Payload Limit = Usable Payload Limit × (1 − Safety Margin ÷ 100)
Cartons by Weight = floor(Safe Payload Limit ÷ Carton Weight)
Cartons per Pallet = min(Cartons by Height, Cartons by Weight)
Pallets Needed = ceil(Total Cartons ÷ Cartons per Pallet)
How to use this calculator
- Enter pallet dimensions, empty pallet height, and tare weight.
- Enter the maximum allowed stack height, payload weight, and gross pallet weight.
- Fill in carton dimensions, carton weight, total cartons, and units per carton.
- Set optional overhang, void factor, and safety margin to reflect real warehouse conditions.
- Choose auto orientation for the best floor pattern, or fixed mode to keep one carton direction.
- Click the calculate button to show results above the form.
- Review cartons per pallet, number of pallets, utilization, and the pallet-by-pallet breakdown.
- Download the CSV or PDF file for warehouse planning, dispatch, or customer approval.
Frequently asked questions
1. What does this pallet load calculator estimate?
It estimates cartons per layer, layers by height, cartons per pallet, pallets needed, shipment cube, and both net and gross weights using your pallet and carton data.
2. Why can weight limit the pallet before height does?
Heavy cartons may reach the safe payload before the stack reaches the maximum height. In that case, the load becomes weight limited rather than height limited.
3. What does the void factor do?
Void factor reduces the practical floor capacity to reflect gaps, wrapping space, label protection, uneven cartons, and other handling allowances that lower real stacking density.
4. Why include a safety margin?
Safety margin creates a reserve below your maximum limits. It helps account for measurement tolerance, handling variability, pallet deflection, and conservative warehouse rules.
5. What is the difference between payload and gross weight?
Payload is cargo weight only. Gross weight includes the cargo plus the empty pallet. Both matter because a shipment can pass one limit and fail the other.
6. Does the auto orientation always give the best real-world pattern?
It gives the better rectangular floor pattern between two basic carton orientations. It does not model pinwheel, interlock, or irregular nesting patterns.
7. Can I use it for mixed-SKU pallets?
Not directly. This version works best for one carton size and weight per calculation. For mixed pallets, calculate each group separately or build a custom mixed-load model.
8. What units does this page use?
The page uses millimeters for dimensions, kilograms for weight, and cubic meters for palletized volume. Keep all entries in the same unit system.