Divide the pallet footprint by the carton footprint in the better of two orientations to get cartons per layer, then multiply by the number of layers that fit under your height limit. A 400 x 300 x 250 mm carton on a EUR 1 pallet (1200 x 800 mm) gives 8 cartons per layer, 6 layers under an 1800 mm limit, and 48 cartons per pallet. The calculator below also checks pallet weight and shows how many pallets and cartons fit in a 20 ft, 40 ft or 40 ft high cube container.
Results are planning figures. Your forwarder or the supplier confirms the final pallet pattern.
How does the calculator work?
- Cartons per layer. It tries each carton orientation on the pallet footprint (cartons per row × rows) and a mixed two-block pattern that fills the leftover strip with the carton turned 90 degrees. It keeps the highest count. Cartons stay inside the pallet edge, so there is no overhang.
- Layers. layers = floor((maximum load height − pallet height) ÷ carton height). The default pallet height is 144 mm, a typical figure for a standard EUR 1 pallet; enter your own if it differs.
- Weight check. gross weight = cartons × carton weight + pallet weight. If that exceeds your maximum pallet weight, the layer count is cut until it fits.
- Container. The same pattern logic places pallets on the container floor. Pallets are stacked on top of each other only if you tick that option and the loaded pallet is low enough.
Pallet sizes: Euro, UK and US
| Pallet | Footprint (mm) | Footprint (in) | Area (m²) | Common in |
|---|---|---|---|---|
| EUR 1 / EPAL 1 | 1200 x 800 | 47.2 x 31.5 | 0.96 | EU, Türkiye to EU road freight |
| EUR 2 / industrial (also the UK standard) | 1200 x 1000 | 47.2 x 39.4 | 1.20 | UK; also used in the EU |
| US GMA | 1219 x 1016 (48 x 40 in) | 48.0 x 40.0 | 1.24 | US |
A EUR 1 pallet and a 1200 x 1000 pallet share the 1200 mm length, so the same carton can give different counts on each. The sourcing guide lists which pallet suits which market, and notes that a trailer typically takes 33 EUR 1 pallets or 26 pallets of 1200 x 1000, single-stacked.
Container internal dimensions and pallets per tier
| Container (typical internal, varies) | Length x width x height (m) | Internal volume (m³) | EUR 1 pallets per tier | 1200 x 1000 pallets per tier | US GMA pallets per tier |
|---|---|---|---|---|---|
| 20 ft | 5.90 x 2.35 x 2.39 | 33.1 | 11 | 9 | 9 |
| 40 ft | 12.03 x 2.35 x 2.39 | 67.6 | 25 | 22 | 20 |
| 40 ft high cube | 12.03 x 2.35 x 2.69 | 76.0 | 25 | 22 | 20 |
Internal sizes are typical and vary by container, so use the figures your shipping line or forwarder gives. The door opening is narrower and lower than the inside, so check it for tall loads. The pallet counts are strict floor patterns with no overhang. Forwarder plans can differ by a pallet or two, and the sourcing guide quotes about 23 to 25 EUR 1 pallets and about 20 to 21 pallets of 1200 x 1000 per tier in a 40 ft container.
Cartons per layer on each pallet
| Carton footprint (mm) | EUR 1 per layer | 1200 x 1000 per layer | US GMA per layer |
|---|---|---|---|
| 600 x 400 | 4 (grid) | 5 (mixed) | 5 (mixed) |
| 400 x 300 | 8 (grid) | 10 (mixed) | 10 (mixed) |
| 300 x 200 | 16 (grid) | 20 (grid) | 20 (grid) |
| 500 x 350 | 4 (grid) | 6 (grid) | 6 (grid) |
| 450 x 300 | 6 (mixed) | 8 (grid) | 8 (grid) |
"Grid" means one orientation in rows. "Mixed" means two blocks, one turned 90 degrees. The carton orientation that gives the best count is not always the obvious one: a 400 x 300 mm carton gives 6 per layer one way and 8 the other on a EUR 1 pallet.
Worked example: 400 x 300 x 250 mm carton, 6 kg
| Step | Result |
|---|---|
| Cartons per layer (best orientation) | 8 |
| Layers allowed by height | floor((1800-144) ÷ 250) = 6 |
| Cartons per pallet | 48 |
| Loaded pallet height | 1644 mm |
| Gross pallet weight | 313 kg |
| Pallets per 20 ft container (one tier) | 11 pallets = 528 cartons |
| Pallets per 40 ft container | 25 pallets = 1200 cartons |
| Pallets per 40 ft high cube | 25 pallets = 1200 cartons |
Pallets are stacked only if the loaded height allows it. At 1644 mm, two loaded pallets do not fit under the 2.39 m internal height of a standard container, so the load is one tier. Total container volume used is about 53 % in the 40 ft case, because the height limit leaves space above the cartons.
A heavier carton changes the limit. At 18 kg and a maximum pallet weight of 800 kg, the same carton gives 5 layers (40 cartons, 745 kg gross) instead of 6, so weight, not height, sets the carton count.
Stacking, overhang and height limits
Column stacking puts every layer in the same pattern, so cartons sit directly over each other and the pallet is strong in compression. Interlock stacking rotates alternate layers so cartons bridge the joints, which can steady a tall load but often leaves gaps or overhang. The calculator counts cartons for column stacking and does not model interlock patterns.
Avoid overhang. Cartons that project past the pallet edge lose compression strength, catch on racking and forklift forks and can be rejected at a warehouse.
Check the maximum load height with your carrier and the receiving warehouse. A road-freight limit of around 2.4 to 2.6 m including the pallet is often quoted as a planning figure, but it depends on the carrier, vehicle and route. Container loads are limited by the internal height and by the carton's own compression strength. Wooden pallets in international trade are normally heat-treated and marked to ISPM 15; confirm destination rules with your forwarder.
What to put in a quotation request
State pallet type, maximum height including the pallet, maximum pallet weight, units per carton and whether ISPM 15 pallets are required. The packaging RFQ guide has the full packing and delivery fields, and packaging lead times explains how packing fits the production schedule.