Enter the box, the pallet and the height and weight limits. The calculator tries the column pattern both ways and block patterns, draws the layer (TI) and the tiers (HI), and tells how many pallets the order takes.
Pre-sizing and estimating tool: results do not replace design, calculations or reports signed by a licensed professional, nor verification against the applicable codes and standards.
To scale. Different colors mark boxes turned 90°. The dashed outline is the limit with the overhang or underhang entered. Heuristic result: a good pattern, not necessarily the optimum.
Column pattern both ways and the best block pattern, with the box upright and, if allowed, on its side.
Each step is one more layer. Maximum gross weight may also cap it. The dashed line is the maximum height entered.
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It finds how many boxes fit per layer (TI), how many layers (HI) and how many boxes per pallet within the maximum height and weight. It draws the layer for whoever builds the pallet and works out how many pallets an order takes. Use it when sizing a new shipper case, filling in a customer pallet pattern or planning shipments.
In a column pattern all boxes face the same way in rows and columns. In a block pattern the layer is split into rectangles with some boxes turned, using the edge strip. In the example, 16 × 12 in cases on a 48 × 40 GMA pallet give 9 per layer in columns and 10 in blocks: 6 one way and 4 turned, covering 100% of the deck.
The pallet takes 10 cases per layer and 5 layers, 50 cases, for a total height of 56 in (6 in pallet + 5 × 10 in) and 1,540 lb gross. The 60 in height limit governs: a sixth layer would exceed it. The 600-case order needs 12 full pallets; a column pattern would need 14.
GMA: 48 × 40 in, the US grocery standard. Euro: 1,200 × 800 mm (47.2 × 31.5 in). Brazil PBR: 1,200 × 1,000 mm. Asia: 1,100 × 1,100 mm. Pallet height and empty weight depend on the maker and material, so adjust the fields to your own.
Only if the packaging allows it. Corrugated boxes carry much more load upright, because the vertical walls act as columns; on their side stacking strength drops sharply. With "This side up: No" the calculator also tries the box lying down and shows whether that fits more.
It depends on racking, trailer, customer receiving rules and bottom box strength. Total heights of 48 to 72 in are common; in a 53 ft van with about 108 in inside height, loads up to 54 in can be double stacked. Gross weight usually stays under 2,000 to 2,500 lb per wood pallet: check with the pallet supplier and your customer.
It is a good pattern, not necessarily the optimum. The calculator finds the best pattern that can be split by successive straight cuts; pinwheel patterns can fit one or two more boxes in some cases. Once the pattern is set, check box compression strength and alternate the layer direction to interlock the load.
Important notice: Indus Metrics tools produce estimates and pre-sizing results from the data you enter and from published engineering methods. They do not replace design, calculations or reports signed by a licensed professional engineer (PE), nor verification against the applicable codes, standards and regulations, such as OSHA rules and the ASME codes. Material and fuel properties vary: check manufacturer data or your own process analyses before deciding. By using this site you agree to the Terms of Use.
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