Pallet build

Cartons per layer

A carton of a × b cm on a pallet of L × W cm fits ⌊L/a⌋ × ⌊W/b⌋ times in columns one way and ⌊L/b⌋ × ⌊W/a⌋ the other way. That is where most calculators stop. Some cartons fit more in mixed rows, a block of columns one way and the rest turned, or in a pinwheel, four blocks around a centre. The tool tries every split along both sides and every pinwheel, keeps the arrangement with the most cartons, and offers the others under the drawing. Ties go to the simpler pattern.

Every second layer is the same pattern turned by 180°. The count and the footprint stay the same and the columns interlock, which is why loaders do it. "Any face down" also tries the carton on its long and its short side and keeps the face that gives the most cartons per pallet, saying which one it chose.

Layers

Three limits, and the smallest one wins: the height cap minus the pallet divided by the carton height; the weight limit minus the pallet divided by the weight of one layer; and the maximum layers you set, if any. The tool names the limit that bound. Height caps are the carrier's or the warehouse's rule, not a law:1.80 m (common groupage limit), 1.50 m (many retail warehouses), 2.00 m (full-truck loads, confirm with carrier), 2.20 m (tall, confirm with carrier). Confirm yours.

Pallets per line, and the part pallet

Cartons on the line divided by cartons per pallet, rounded up. The remainder goes on a part pallet with its own layers, height and weight, and is handed to Trailer fit as its own row because a shorter pallet may stack where a full one cannot. Every weight is shown as goods + pallet = gross, so the pallet's own weight is never a surprise on the scale.

Pallets

Weights are EPAL's "approx." figures, and a wooden pallet's weight moves with its moisture. The lightweight one-way "Euro size" pallets sold for export weigh less, carry less and are a different product. The safe working load is for an evenly distributed load; the half pallet (EPAL 6) is rated 750 kg on EPAL's current page, 500 kg on older cards. Edit any of these if your pallets differ.

What the tool leaves out

Mixed pallets with several carton sizes on one pallet: the packing order and the crush strength of the bottom cartons decide those, and a drawing that ignores both would mislead. Crush strength in general, stretch wrapping, load securing, dangerous goods, and your carrier's or warehouse's own limits. Loading meters come from the footprint by the Trailer fit convention (footprint ÷ 2.4 m: 0.4 for a Euro pallet, 0.5 for an industrial one).

Disclaimer

Pallet build is a free planning aid, provided as is and without warranty. It arranges rectangles: it does not assess carton crush strength, stretch wrapping, load securing, dangerous-goods rules, or any carrier’s or warehouse’s own height, weight and overhang limits, which vary and must be confirmed with them. Pallet dimensions, weights and safe working loads are EPAL’s nominal figures, approximate (wood moisture alone moves a Euro pallet between about 20 and 25 kg) and valid for evenly distributed loads; lightweight one-way pallets of the same size are a different product. Overhang reduces stacking strength. The result is a plan, not a packing instruction, and not professional advice. Verify every figure with your carrier and your own measurements before relying on it. No liability is accepted for decisions, costs or damage arising from its use, to the extent permitted by law. EPAL and carrier names identify published documents only; the tool is independent of, and not endorsed by, any of them, and all trademarks belong to their owners.

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