Box & Pallet Load Calculator
A EUR pallet (120 x 80 cm) loaded to 150 cm holds 48 cartons of 40 x 30 x 25 cm (8 per layer, turned 30 x 40), filling about 100% of the load volume. For mixed boxes the result is a good plan, not a proven maximum.
How to use
- Pick a pallet or container preset, or choose Custom and type the inner length, width and the maximum loading height. Add a weight limit if the pallet or container has one. Switch between cm and in; weights follow as kg or lb.
- List each box type with its length, width, height, quantity and weight. Tick "Any rotation" if the box may lie on any side. Leave it off for "this side up" cartons, which can still turn 90 degrees on the floor. Tick "Nothing on top" for fragile boxes.
- Read how many boxes were loaded and how many were left out, the volume fill and the total weight. Drag the slider to turn the 3D view. Each color is one box type.
How it works
Boxes are placed one at a time with an extreme-point heuristic, the same idea used for 3D bin packing. Boxes are sorted largest first. Each box tries the corners left by the boxes already placed, drops down until it rests on the floor or on another box, and takes the lowest, then front-most position where it fits.
A box needs at least 70% of its base resting on boxes below, so nothing hangs in the air, and it never goes on top of a box marked "Nothing on top". With rotation off a box keeps its height and may only turn 90 degrees on the floor. With rotation on all six orientations are tried.
The tool runs six combinations of sort order and orientation preference and keeps the plan that loads the most boxes. Volume fill is the volume of loaded boxes divided by length x width x maximum height. If a weight limit is set, a box that would push the total over it is left out and lighter boxes are still tried.
This is a heuristic, not an exact solver. Finding the true maximum is NP-hard, so a skilled packer can sometimes fit a few more boxes with interlocking patterns. It does not model box strength, the weight of the pallet itself, load stability under transport or the center of gravity.
Common pallet and container sizes
| Type | Footprint or inner size | Typical use |
|---|---|---|
| EUR pallet | 120 x 80 cm | Europe, rail and truck freight |
| ISO pallet | 120 x 100 cm | Drums, chemicals, export |
| US (GMA) pallet | 48 x 40 in (122 x 102 cm) | North America grocery and retail |
| 20 ft container | 589.8 x 235.2 x 239.3 cm inside | Dense or heavy cargo |
| 40 ft container | 1203.2 x 235.2 x 239.3 cm inside | General cargo |
| 40 ft high cube | 1203.2 x 235.2 x 269.8 cm inside | Light, bulky cargo |
Getting more onto the pallet
- Try cartons in both directions. A 40 x 30 cm base fits 8 per layer on a EUR pallet when the 40 cm side runs across the 80 cm width and 6 the other way, so allow 90 degree turns.
- Check the height limit last. Extra height only helps when a whole new layer fits, so lowering the limit by one box height often changes nothing.
- Keep heavy boxes low. The plan fills the floor first, but you should still check weight distribution before loading.
FAQ
Is this the maximum number of boxes that can fit?
Not always. It is a fast heuristic that tries six strategies and keeps the best. For cartons of one size it is usually at or near the best layered pattern, but hand-built interlocking patterns can sometimes add a box or two. Treat the count as a realistic plan and test the first pallet.
What are the standard pallet and container sizes?
A EUR pallet is 1200 x 800 mm and a US (GMA) pallet is 48 x 40 in. Typical inner sizes are about 5.90 x 2.35 x 2.39 m for a 20 ft container, 12.03 x 2.35 x 2.39 m for a 40 ft container and 12.03 x 2.35 x 2.70 m for a 40 ft high cube. Exact sizes vary a little by maker, so check yours.
Is the pallet height counted?
No. Enter the maximum height of the load itself, above the pallet deck. A common limit is 150 to 180 cm including the pallet, so subtract the pallet height, about 14.4 cm for a EUR pallet.
How does the weight limit work?
It is a hard limit. Boxes that would push the total over it are not loaded and are counted as left out because of weight. The tool also warns when all the boxes you entered weigh more than the limit. Container payload limits are set by the shipping line and the box itself, so check the data plate.
What does "Nothing on top" do?
Other boxes are never placed on that box. It is useful for fragile goods or boxes marked do not stack. The box can still sit on top of others.
Why did a box not fit when there seems to be space?
The free space may be split into gaps smaller than the box, or a box would need more than 30% of its base unsupported. Tick "Any rotation" for boxes that may lie on any side, or reduce the pallet height limit to see what changes.