Pallet / Box Loading Calculator

Total boxes per pallet from pallet length

Pallet length	48
Pallet width	40
Maximum stack height	60
Pallet thickness (inches)	6
Box length	16
Box width	12
Box height	10
Total boxes per pallet	45
Volume utilization	83.3%

Pallet / Box Loading: formula

Boxes per layer = floor(pallet length ÷ box length) × floor(pallet width ÷ box width); layers = floor(max height ÷ box height)

U.S. SBA: manage your finances · FedEx: Pallet packing guide

Common error: Dividing the pallet volume by the box volume. Boxes cannot be cut to fit, so the real count is lower than the ratio suggests.

Enter pallet length and width, the maximum overall loaded height, actual pallet thickness and box outside dimensions. The entered six-inch thickness is an example assumption. Boxes keep the entered orientation; rotate length and width yourself to compare a second layout.

Check carrier weight and stability requirements separately.

Pallet / Box Loading: changing Pallet length

Total boxes per pallet: assumed Pallet length scenarios.
Pallet length	Total boxes per pallet	Volume utilization
38	30	70.2%
43	30	62.0%
48 (example)	45	83.3%
53	45	75.5%
58	45	69.0%

Pallet / Box Loading: compare input ranges

Pallet / Box Loading Calculator: Total boxes per pallet with each input moved on its own, every other input held at the worked-example value.
Input	Tested from	To	Total boxes per pallet: low input	Total boxes per pallet: high input	Swing
Pallet length	43	53	30	45	15 (33%)
Maximum stack height	54	66	36	54	18 (40%)
Box length	14	18	45	30	15 (33%)
Box height	9	11	54	36	18 (40%)
Pallet width	36	44	45	45	0
Pallet thickness (inches)	5.4	6.6	45	45	0
Box width	11	13	45	45	0

Pallet / Box Loading: individual input comparisons

Pallet / Box Loading Calculator: change one input at a time; other values remain at the stated example.
Input	Value	Total boxes per pallet	Volume utilization
Pallet length	38	30	70.2%
	43	30	62.0%
	48	45	83.3%
	53	45	75.5%
	58	45	69.0%
Pallet width	32	30	69.4%
	36	45	92.6%
	40	45	83.3%
	44	45	75.8%
	48	60	92.6%
Maximum stack height	48	36	85.7%
	54	36	75.0%
	60	45	83.3%
	66	54	90.0%
	72	54	81.8%
Pallet thickness (inches)	4.8	45	81.5%
	5.4	45	82.4%
	6	45	83.3%
	6.6	45	84.3%
	7.2	45	85.2%
Box length	13	45	67.7%
	14	45	72.9%
	16	45	83.3%
	18	30	62.5%
	19	30	66.0%
Box width	10	60	92.6%
	11	45	76.4%
	12	45	83.3%
	13	45	90.3%
	14	30	64.8%
Box height	8	54	80.0%
	9	54	90.0%
	10	45	83.3%
	11	36	73.3%
	12	36	80.0%

Total boxes per pallet: Pallet length against Pallet width

Pallet / Box Loading: Total boxes per pallet at combined Pallet length and Pallet width settings.
Pallet length / Pallet width	32	40	48
38	20	30	40
43	20	30	40
48	30	45	60
53	30	45	60
58	30	45	60

Pallet / Box Loading: values and definitions

Worked-example inputs and the results they produce for the Pallet / Box Loading Calculator.
Quantity and definition	Value used
Pallet length — Pallet length, in inches (48 is standard GMA).	48
Pallet width — Pallet width, in inches (40 is standard GMA).	40
Maximum stack height — Maximum allowed load height including the pallet, in inches.	60
Pallet thickness (inches) — Measure your pallet; six inches is an example assumption, not a standard.	6
Box length — Box length, in inches.	16
Box width — Box width, in inches.	12
Box height — Box height, in inches.	10
Total boxes per pallet	45
Volume utilization	83.3%

Pallet length: half and double

Pallet / Box Loading scale comparison; assumed inputs.
Pallet length	Total boxes per pallet
24	15
48	45
96	90

The percentage excludes the pallet’s own thickness and describes box volume inside the available rectangular load space. It does not certify stacking strength, restraint, forklift access, gross weight or carrier acceptance. Mixed or interlocked patterns require a separate layout.

Pallet planning is a packing problem: how many boxes fit on the base and how many layers fit under the height limit. A 48 by 40 inch pallet takes 3 boxes of 16 inches along its length and 3 of 12 inches across, so 9 per layer, and with a 60 inch limit and 10 inch boxes there are 6 layers, or 54 boxes. That uses about 90 percent of the available volume.

Turning the boxes could change the count, and the layout is worth testing.

Include the pallet's own height in the limit, and check the weight rating. Many pallets reach their weight limit before they reach their height limit.

Estimate shipping volume and cost with the cubic feet calculator and the unit-conversion pages, and connect to inventory decisions with the economic order quantity calculator. For bulky items, compare full pallets with parcel shipping. Confirm the load with your carrier before shipping.

Does the 60-inch limit include the pallet?

Yes. The calculator subtracts the entered pallet thickness before counting whole box layers.

Does nine boxes per layer prove the load can ship?

No. Weight, crushing strength, stability and carrier packaging rules remain separate. FedEx’s pallet guide also calls for avoiding unsupported overhang.

Pallet / Box Loading Calculator