How Many Boxes Fit on a Pallet? Layers, Height and Weight

Palletising cartons efficiently saves warehouse space, freight cost and handling time. The question is simple: how many boxes fit on a pallet? The answer depends on pallet size, box size, height limits and weight. This guide shows the calculation step by step, with our free Pallet Loading Calculator.

Common pallet sizes

Pallet	Size	Used in
Standard (ISO)	1,200 × 1,000 mm	Asia, Middle East, many exports
Euro pallet (EUR)	1,200 × 800 mm	Europe
North American	48 × 40 in (1,219 × 1,016 mm)	USA, Canada

Step 1: Boxes per layer

Divide pallet length and width by box length and width, and try both orientations.

Box: 40 × 30 × 25 cm on a 120 × 100 cm pallet:

Orientation	Calculation	Boxes per layer
40 along 120, 30 along 100	3 × 3	9
30 along 120, 40 along 100	4 × 2	8

Mixed patterns can sometimes fit an extra box; read pallet stacking patterns.

Step 2: Number of layers

Subtract the pallet’s own height (about 15 cm) from the maximum load height.

If the total height limit is 150 cm: 150 − 15 = 135 cm. 135 ÷ 25 = 5.4, so 5 layers.

Step 3: Total boxes

9 × 5 = 45 boxes per pallet.

Step 4: Check weight

If each box weighs 18 kg: 45 × 18 = 810 kg, plus about 25 kg for the pallet = 835 kg. Check the pallet’s rated load and the weight the bottom boxes can bear. See box strength tests.

Avoid overhang

Boxes hanging over the pallet edge lose much of their stacking strength and are easily damaged. Underhang of a few centimetres is safer.

Height limits

Warehouses, racks, trucks and containers have height limits. A 20 ft container’s internal height is about 2.39 m, allowing double stacking only for low pallets.

For pallet capacity in containers, see the Pallet Capacity Calculator. Wrap the load properly with the Pallet Wrap Calculator.

Frequently asked questions