How many boxes fit on a pallet?
Boxes per pallet = boxes per layer × number of layers, as long as you stay within the weight limit. The hard part is getting the most boxes into each layer.
Updated October 2026
What you need to know first
- Pallet size, for example 1200 × 1000 mm (UK), 1200 × 800 mm (Euro) or 48 × 40 in (US). See pallet sizes.
- Box size: length, width and height of the outer carton.
- Maximum total height, measured from the floor, including the pallet deck.
- Maximum weight for the load, and the weight of one box.
- Whether boxes must stay this way up, or can be laid on their side.
Step 1: boxes per layer
Divide the pallet length by the box length and the pallet width by the box width, round each down, and multiply. Then try again with the box turned 90°, because one way round often fits better than the other.
Simple division often leaves a strip of wasted space. Mixed patterns, with some boxes turned 90° to fill that strip, can fit more. That is the step most people miss, and it is where a calculator earns its keep.
Step 2: number of layers
Take the maximum total height, subtract the pallet deck height, divide by the box height and round down. That is how many full layers fit.
Step 3: check the weight
Multiply boxes per layer by layers to get the total, then check total weight against your limit. If it is over, the weight limit (not space) decides how many boxes you can send.
Worked example: UK pallet
A UK 1200 × 1000 mm pallet with a 15 cm deck, a 1.8 m total height limit, and boxes of 40 × 30 × 30 cm that must stay upright:
| Straight grid, 40 cm along the 120 cm side | 3 × 3 = 9 per layer |
| Turned 90° | 4 × 2 = 8 per layer |
| Mixed: two rows one way, the rest turned | 10 per layer |
| Layers: (180 − 15) ÷ 30 | 5 layers (165 cm total) |
| Boxes per pallet | 50 |
The mixed pattern fits 5 more boxes per pallet than the simple grid: that is 10% more on every pallet you ship.
Worked example: US 48 × 40 pallet
A 48 × 40 in pallet with a 6 in deck, a 72 in total height limit, and 16 × 12 × 10 in boxes weighing 30 lb each:
| Step | Result |
|---|---|
| Straight grid | 3 × 3 = 9 per layer |
| Mixed pattern | 10 per layer |
| Layers: (72 − 6) ÷ 10 | 6 layers (66 in total) |
| Boxes per pallet | 60 |
| Weight: 60 × 30 lb | 1,800 lb plus the pallet |
Mistakes to avoid
- Forgetting the pallet deck when working out layers. Height limits are almost always total height from the floor.
- Ignoring box strength. Just because ten layers fit does not mean the bottom boxes can carry them. Check the carton's stacking strength.
- Overhang. Boxes past the pallet edge are easily damaged, and carriers measure to the outermost point.
- Mixed box sizes. With several box sizes the maths gets hard fast: you need to decide what goes on which pallet, keep heavy boxes low and make sure every box is properly supported. That is what the full PalletBrain calculator does for you.
Do it in seconds
Enter your box and pallet in the free pallet calculator to get boxes per layer, layers, total and weight, with a diagram of the best layer pattern.
Get a quick answer for one box size with no signup, or create a free account for mixed boxes, a 3D load plan and exports.