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Pallet Configuration Calculator
Updated October 21, 2026
Boxes per pallet = TI (boxes per layer) × HI (layers). 12 × 10 × 8 in boxes on a 48 × 40 pallet stack 16 per layer, 6 layers high under 60 in: 96 boxes. Enter your box and pallet below.
Boxes per pallet: TI × HI
The calculator tries both box orientations, keeps every box the same way in a layer, and stacks layers in columns with no overhang. Mixed or interlocked patterns can sometimes fit one or two more boxes per layer. 60 in is an example height limit; use your carrier’s or warehouse’s limit.
How to calculate a pallet configuration
- TI (boxes per layer):
floor(pallet length ÷ box length) × floor(pallet width ÷ box width). Try it with the box turned 90° too and keep the larger number. - HI (layers):
floor((max height − deck height) ÷ box height), then fewer if a weight limit is reached first. - Boxes per pallet = TI × HI.
Worked example 1: 12 × 10 × 8 in boxes on a 48 × 40 pallet, 60 in max height, 5.5 in deck: TI = 4 × 4 = 16, HI = floor(54.5 ÷ 8) = 6, so 96 boxes, covering 100% of the deck at 53.5 in tall.
Worked example 2: 16 × 12 × 10 in boxes on the same pallet: lengthwise 3 × 3 = 9, turned 4 × 2 = 8, so TI = 9; HI = floor(54.5 ÷ 10) = 5; 45 boxes, 90% deck coverage. With 40 lb boxes and a 1,500 lb limit, HI drops to floor(1,500 ÷ 360) = 4, so 36 boxes.
Standard pallet sizes (ISO 6780)
| Size (mm) | Inches | Common in |
|---|---|---|
| 1219 × 1016 | 48 × 40 | North America (GMA) |
| 1200 × 1000 | 47.24 × 39.37 | Europe, Asia |
| 1200 × 800 | 47.24 × 31.50 | Europe (EUR) |
| 1067 × 1067 | 42 × 42 | North America, Europe, Asia |
| 1100 × 1100 | 43.31 × 43.31 | Asia |
| 1140 × 1140 | 44.88 × 44.88 | Europe |
Once you know the boxes per pallet, use the pallet weight calculator for the gross weight and density, and the pallets per truck calculator for trailer and container counts.
Sizes as of October 21, 2026, from ISO 6780:2003, Flat pallets for intercontinental materials handling (six principal dimensions). The about 5.5 in GMA pallet height is from the packagingtools.io pallet stacking optimizer. Inch conversions are rounded to 0.01 in.
FAQ
What does TI x HI mean?
TI is the number of boxes in one layer (tier) on the pallet, and HI is the number of layers (high). Boxes per pallet = TI × HI. For example, 16 × 6 = 96 boxes.
How many boxes fit on a 48x40 pallet?
It depends on the box size and height limit. 12 × 10 × 8 in boxes fit 16 per layer and 6 layers under 60 in, for 96 boxes.
What is the standard pallet size?
In North America it’s 48 × 40 in (the GMA pallet). ISO 6780 lists six sizes, including 1200 × 800 mm (EUR) and 1200 × 1000 mm.
Should boxes overhang the pallet?
Generally no. Overhang lets box edges carry load without support, which can crush corners. This calculator only counts boxes that fit fully on the deck.
Why does the calculator turn the box?
Turning the box 90° can fit more per layer. The calculator tries both ways and shows the better one.