How Many Cartons Fit on a Pallet?

What it depends on

• Pallet footprint: in the U.S. usually 48 x 40 in., the dominant standardized size.^[4]
• Carton dimensions and whether overhang is allowed (usually not).
• Maximum pallet height set by the receiver, the trailer and the racking.
• Carton strength: the Hi stops where safe weight or height limits are reached.^[2]
• Maximum pallet weight and the receiver's pallet rules.

Worked example: 16 x 12 x 10 in. cartons on a 48 x 40 pallet

Ti, cartons per layer. With the 16 in. side along the 48 in. edge: 48 / 16 = 3 and 40 / 12 = 3.3, so 3 x 3 = 9. Turned the other way: 48 / 12 = 4 and 40 / 16 = 2.5, so 4 x 2 = 8. A mixed layer does better: one row of 4 cartons turned (4 x 12 = 48 in. wide, 16 in. deep) plus two rows of 3 (3 x 16 = 48 in. wide, 12 in. deep each) fills 16 + 12 + 12 = 40 in. exactly, for a Ti of 10.

Hi, layers. Say the receiver allows 60 in. overall and the pallet itself is 5.5 in. tall: (60 - 5.5) / 10 = 5.45, so the Hi is 5.

Cartons per pallet: 10 x 5 = 50. At 22 lb per carton that is 1,100 lb of product plus the pallet, which the pallet, the cartons and the receiver's weight limit all have to allow.

Pattern and stability

In retail terms the result is written as a Ti-Hi: "A 'TIxHI' of 12x5 = 12 units per layer, 5 layers per pallet."^[1] Mixed or interlocked layers tie the stack together but put more load on the carton walls, while column stacking keeps the strength at the corners; the trade-off is explained in how a damaged pallet gets rebuilt. Whatever the pattern, stacked material has to be stable and secure against sliding or collapse.^[3]

Limitations

A retailer's published Ti-Hi for an item overrides the arithmetic. Bulging cartons, corner boards and label placement can each cost a carton per layer, and a heavy product may be limited by weight before height.