How Many Boxes Fit on a Pallet? Calculator + Configuration Guide
Calculate how many cartons, cases, or boxes fit on a standard 48×40 pallet. Formula, reference tables by carton size, weight limits, and a free pallet calculator that gives you Ti Hi configuration instantly.
⚡ Quick formula
How to Calculate Boxes Per Pallet
The calculation has two parts: how many boxes fit in one layer (Ti), and how many layers you can stack (Hi). Multiply them together and you have the total boxes per pallet.
Step 1: Calculate cartons per layer (Ti)
Divide the pallet's usable length by the carton length and round down. Then divide the pallet's usable width by the carton width and round down. Multiply the two results.
Across (48" ÷ 14") = floor(3.43) = 3
Deep (40" ÷ 10") = floor(4.0) = 4
Ti = 3 × 4 = 12 cartons per layer
Flip orientation: 48" ÷ 10" = 4, 40" ÷ 14" = 2 → Ti = 8
Use 12 (original orientation wins)
Step 2: Calculate layers (Hi)
Subtract the pallet board height (5.5 inches for a standard GMA pallet) from your maximum pallet height, then divide by carton height and round down.
Usable stack height = 60" − 5.5" = 54.5"
Hi = floor(54.5 ÷ 8) = floor(6.8) = 6 layers
Step 3: Total boxes
Cartons Per Layer Reference Table — Standard 48×40 Pallet
Common carton sizes and the Ti (cartons per layer) they produce on a standard GMA 48×40 pallet. Both orientations tested — the higher result is shown.
| Carton L×W (inches) | Ti (cartons/layer) | At 5 layers (50" pallet) | At 6 layers (55" pallet) |
|---|---|---|---|
| 8" × 6" | 30 | 150 | 180 |
| 10" × 8" | 24 | 120 | 144 |
| 12" × 10" | 16 | 80 | 96 |
| 12" × 8" | 20 | 100 | 120 |
| 14" × 10" | 12 | 60 | 72 |
| 16" × 12" | 9 | 45 | 54 |
| 18" × 12" | 8 | 40 | 48 |
| 20" × 16" | 6 | 30 | 36 |
| 24" × 20" | 4 | 20 | 24 |
Based on 48×40 GMA pallet. Pallet board 5.5" subtracted before Hi calculation. Both orientations tested.
Standard Pallet Sizes and Usable Dimensions
The calculation above uses a 48×40 GMA pallet — the most common in North American grocery, retail, and general freight. Other pallet sizes change the Ti calculation significantly.
| Pallet type | Dimensions | Common use | Max height (typical) |
|---|---|---|---|
| GMA Standard | 48" × 40" | US grocery, retail, general freight | 60" |
| Euro Pallet (EUR1) | 47.2" × 31.5" | European retail, international | 86.6" (2200mm) |
| Square Pallet | 48" × 48" | Paint, beverages, cylindrical goods | 60" |
| Half Pallet | 48" × 20" | Club stores, display pallets | 48" |
Weight Limits — Don't Let Ti Hi Exceed the Weight Cap
A mathematically correct Ti Hi can still produce an overweight pallet. Always check pallet weight after calculating configuration:
| Limit type | Max weight | Applies to |
|---|---|---|
| LTL carrier standard | 2,000 lbs | Most LTL carriers — per pallet |
| GMA pallet rated load | 2,500 lbs | Static load capacity of GMA 48×40 |
| Retail DC racking | 1,500 lbs | Walmart, Target, most retail DCs |
| Forklift capacity | 3,000–5,000 lbs | Varies by forklift model |
To check pallet weight: multiply total cartons by carton weight, then add the pallet board weight (GMA standard ~45 lbs). If you're over the limit, reduce Hi by one layer and recalculate.
Why Getting Pallet Configuration Right Saves Money
Under-palletising — shipping fewer cartons per pallet than physically possible — is one of the most common and avoidable freight cost increases in warehouse operations. Every extra pallet means another pallet charge, more linear feet, potentially another LTL shipment, and more handling at the DC.
| Scenario | Cartons/pallet | Pallets for 1,000 cartons | Freight impact |
|---|---|---|---|
| Optimised (Ti 12, Hi 6) | 72 | 14 pallets | Baseline |
| Partial stack (Ti 12, Hi 4) | 48 | 21 pallets | +50% pallets |
| Under-palletised (Ti 6, Hi 3) | 18 | 56 pallets | 4× the freight cost |
How to Use the Free Pallet Calculator
The CargoTools pallet calculator handles all of this automatically. Enter your carton dimensions and weight, select your pallet size and maximum height — it returns:
- Ti (cartons per layer) — with best orientation selected automatically
- Hi (number of layers) — based on your height limit
- Total cartons per pallet
- Total pallet weight including pallet board
- Whether you're over the 2,000 lb carrier weight limit
It supports 48×40 GMA, 48×48, Euro (1200×800mm), and fully custom pallet sizes. No signup required.
Calculate Boxes Per Pallet Free
Enter carton dimensions and pallet size — get Ti Hi configuration, total cartons, and pallet weight instantly.
Open Free Pallet Calculator →Frequently Asked Questions
How many boxes fit on a standard pallet?
It depends entirely on carton size. On a 48×40 GMA pallet: a 12×10" carton fits 16 per layer; at 6 layers that's 96 cartons. A 20×16" carton fits 6 per layer; at 5 layers that's 30. Use the free pallet calculator with your exact dimensions.
How do I calculate how many cartons fit on a pallet?
Ti = floor(48 ÷ carton L) × floor(40 ÷ carton W) — try both orientations, use the higher result. Hi = floor((max pallet height − 5.5") ÷ carton H). Total = Ti × Hi. Check pallet weight doesn't exceed 2,000 lbs.
How many cases fit on a 48×40 pallet?
Common results: 12×10" cases = 16 per layer; 16×12" cases = 9 per layer; 12×8" cases = 20 per layer. Multiply by your Hi (layers) for the total. The reference table above covers the most common case sizes.
What is the maximum weight of a pallet?
Most LTL carriers cap pallet weight at 2,000 lbs including the pallet board (~45 lbs). Retail DCs typically cap at 1,500–2,000 lbs for racked storage. Always check your carrier's and retailer's specific requirements before finalising configuration.
How many boxes fit on a Euro pallet?
A Euro pallet (1200×800mm = 47.2"×31.5") is smaller than the US GMA 48×40. For a 300×200mm carton: 4 across × 4 deep = 16 per layer. Use the pallet calculator and select Euro pallet for exact results with your carton dimensions.