Pallet Loading Calculator

Plan a pallet in 3D with as many different carton sizes as you actually ship. Set your pallet, height limit, and weight cap, and get cartons per layer, layers per pallet, stacked height, gross weight, density, and how many pallets the order needs.

Interactive 3D view Multiple carton sizes Layer by layer patterns

3D pallet loading calculator

Add as many different carton sizes as you ship, set your pallet, height, and weight limits, and see the mixed size pallet build layer by layer in 3D with cartons per pallet, stacked height, gross weight, and pallets needed.

Carton sizes

L (in)

W (in)

H (in)

Weight (lbs)

Qty in order

40 on this pallet

L (in)

W (in)

H (in)

Weight (lbs)

Qty in order

48 on this pallet, 12 left over

Pallet and limits

Pallet size

Pallet length (in)

Pallet width (in)

Deck height (in)

Pallet tare (lbs)

Max stack height (in)

Max gross weight (lbs)

Allow cartons to be rotated 90 degrees within a layer

Show layers9 / 9

Cartons on this pallet

Layers

Cartons in layer shown

Stacked height

95.5 in

Gross weight

1,640 lbs

Footprint used

90%

Cube used

90%

Density

15.46 PCF

Pallets for the order

Cartons in order

100

Mixed size results use block patterns with no slip sheets, void fill, or overhang, and heavier cartons should be planned into the lower layers on the dock. Pallet count for the order is an estimate that assumes each pallet builds like the one shown. If your cartons overhang the deck, add the overhang to the footprint you tender, because that is the footprint the carrier will dimension.

Load it clean

Tips for stable mixed size pallets

Group similar heights per layer

With different carton sizes the layer height is set by the tallest carton in it. Putting similar heights together buys you extra layers inside the same limit.

Keep the load inside the edges

Zero overhang. Even one inch hanging past the deck sheds stack strength and pushes the dimensioned footprint up on every quote.

Heavy cartons on the bottom

Load the dense sizes in the lower layers and the light bulky sizes on top. The math allows either, the crush strength does not.

Plan for double stacking early

If you want two pallets high in a dry van, hold each pallet near 48 to 52 inches and cap the top so a second pallet can ride on it.

Watch the weight cap, not just height

Heavy cartons hit the pallet rating before they hit the height limit. Plan to about 2,000 to 2,200 pounds on a standard GMA pallet.

Put the pattern on the paperwork

Pieces per pallet by size, pallet count, dimensions, and gross weight on the BOL keep the carrier from redimensioning you and give the receiver a count to check.

A quick worked example

An 18 by 12 by 10 inch carton at 22 pounds on a 48 by 40 pallet fits 8 per layer with a dead strip left on the deck. Add a second size, 12 by 12 by 10 at 15 pounds, and that strip fills instead of riding empty, so the same 96 inch height limit moves noticeably more units per pallet. Rotate the 3D view and step through the layers to see exactly where the space went.

Reference

Common pallet sizes

The 48 by 40 inch GMA pallet is the North American default and the size most trailer and rack layouts assume. Everything else exists for a reason, usually drums, export lanes, or a specific industry standard.

Pallet (in)	Footprint (sq ft)	Typical use
48 x 40	13.3	GMA standard, grocery, retail, general dry freight
48 x 48	16.0	Drums and cylindrical freight
42 x 42	12.3	Paint, telecom, some beverage lanes
48 x 45	15.0	Automotive parts
40 x 48	13.3	Same deck as GMA, loaded turned in the trailer
47.24 x 31.5	10.3	Euro EUR1, export and intra Europe lanes
36 x 36	9.0	Beverage, small footprint retail displays

Inside FreightCanvas

How palletizing fits the FreightCanvas workflow

This page is the standalone version of the palletizing step inside FreightCanvas. Inside the app the pallet you build here becomes a freight item on the trailer, so the same numbers carry through class, route, fuel, and the quote you send.

Pallets become freight items

Send a calculated pallet into the Load Visualizer as a freight item with its footprint, stacked height, and gross weight, then place it in 2D or 3D and auto fit the trailer.

See the Load Visualizer

Density feeds classification

Gross weight and cube from your mixed size pattern are exactly what the freight class step needs, so the suggested NMFC class updates as you change carton sizes or layers.

Freight class calculator

Trailer, route, and fuel

Pallet counts drive how many trailers you need, and truck aware multi stop routing with hazmat handling and per state fuel estimates gives the trip cost beside the freight.

See routing

Axle and weight checks

Heavy pallets in the wrong spot fail a scale, not a spreadsheet. Placement in the visualizer tracks section weights and axle limits as you load.

Plan a load

Quotes and BOLs inherit the counts

Pieces per pallet, pallet count, dimensions, and weights flow into the quote builder and the Bill of Lading, so the paperwork matches what you tendered.

See documents

Reusable pallet patterns

Save a pattern per SKU or customer and reuse it on the next order instead of rebuilding the math for freight you ship every week.

Saved layouts

Why brokers and shippers sign up

Turn pallets into 2D and 3D trailer load plans with axle and section weights
Truck aware routing with hazmat handling and per state fuel estimates
Quotes, Bills of Lading, and load plan PDFs that inherit your counts
Saved layouts and customers so repeat freight is one click

Start free trial See pricing

No credit card needed. The calculator on this page stays free and open to everyone.

The basics

What a pallet pattern decides for you

Palletizing is the point where packaging turns into freight cost. The pattern sets how many units ride on each pallet, how many pallets go on the trailer, how stable the stack is on a dock, and the density carriers use to class and rate the shipment. Mixed carton sizes are where most of the hidden space is, which is why this tool plans them together in 3D instead of one size at a time.

Cartons per pallet, by size

Mixed size builds tell you how many of each carton actually rides on the deck, so case packs, purchase orders, and pick lists are built on the real number instead of an average.

Cube utilization

Wasted deck space and wasted headroom are both paid freight. Different carton sizes let you fill the strips a single size pattern leaves empty.

Density and class

Gross weight divided by the cube of the stacked pallet gives pounds per cubic foot, which drives the NMFC class on most general commodities.

Stability and damage

Column stacked corners carry load and overhang throws it away. In 3D you can see a mixed size layer that leaves a carton unsupported before the dock finds out.

Pallet loading FAQ

Can this pallet calculator handle different carton sizes on one pallet?

Yes. Add as many different carton sizes as you ship, each with its own length, width, height, weight, and order quantity. The packer mixes those sizes across every layer, fills leftover strips with the smaller cartons, and reports how many of each size landed on the pallet and how many are left over for the next pallet.

What does the 3D view show me?

The 3D view renders the actual pallet build, color coded by carton size, so you can orbit the stack and inspect layer by layer with the layer slider. It is the fastest way to see wasted headroom, a dead strip on the deck, or a mixed size layer that will not be stable on a dock.

How do you calculate how many boxes fit on a pallet?

Fit the carton footprints into the pallet footprint to get each layer, then keep adding layers until you hit the usable stack height or the weight cap. Usable height is your trailer or warehouse limit minus the pallet deck height. With mixed sizes the layer height is set by the tallest carton in that layer, which is why grouping similar heights together loads better.

How tall can a pallet be stacked?

For a dry van most shippers plan 96 to 100 inches gross including a 5 to 6 inch pallet deck, which leaves about 90 inches of product. Double stacked LTL freight is often held to 48 to 52 inches per pallet so two fit in the same door height. Set the limit you actually ship to.

How much weight can a standard 48x40 pallet hold?

A new GMA hardwood pallet is commonly rated near 2,500 pounds of evenly distributed static load, and many shippers plan 2,000 to 2,200 pounds to leave margin for used pallets and uneven stacks. Confirm the rating with your pallet supplier before planning to the limit.

Should cartons overhang the pallet?

No. Overhang sheds a large share of stacking strength, invites damage, and carriers dimension the footprint the freight actually occupies, so an overhanging load is rated on the bigger footprint. Pick carton sizes that divide into the deck, or step down a pallet size.

Does a tighter pallet pattern lower my freight cost?

Usually yes for LTL. More cartons per pallet raises density in pounds per cubic foot, and density drives the NMFC class for most general commodities. Consolidating two half filled pallets of mixed carton sizes into one tight pallet can move you down a class band on identical freight.

Results are planning guidance. Confirm pallet load ratings with your pallet supplier and confirm height, weight, and stacking limits with your carrier before you tender.