Uniform Pallet Layer Calculator

This is a uniform-grid estimate: every carton in a layer uses the same orientation. It is not a mixed pattern or pallet-stability plan.

How to use it: pick a standard pallet preset or enter a custom footprint, then enter the carton's footprint and height and the maximum stack height you're allowed to load to. The layout, per-layer count, layer count and total update immediately. Editing either pallet dimension by hand switches the preset back to "Custom".

Formula. The tool builds two candidate grids - cartons placed "normal" and cartons rotated 90° in plan - and keeps whichever fits more per layer:

Normal: cols = floor(palletW / cartonW), rows = floor(palletL / cartonL)
Rotated: cols = floor(palletW / cartonL), rows = floor(palletL / cartonW)

Whichever grid has the higher cols × rows is used as the per-layer count (ties keep the normal orientation). Layers and total then follow from the height limit:

layers = floor(maxLoadHeight / cartonH) and total cartons = perLayer × layers

Worked example. With the defaults (1000×1200 mm pallet, 300×400×250 mm cartons, 1500 mm max height): normal grid = floor(1000/300)=3 × floor(1200/400)=3 = 9 per layer; rotated grid = floor(1000/400)=2 × floor(1200/300)=4 = 8 per layer. 9 is larger, so the normal orientation is used. Layers = floor(1500/250) = 6, giving a total of 9 × 6 = 54 cartons.

This tool compares exactly two layouts - a uniform normal grid and a uniform 90°-rotated grid - it is not a mixed-orientation nesting optimizer. Real pallet patterns sometimes interlock rows in different orientations (pinwheel patterns, for example) to use space this tool can't find.

Every layer uses the same full-height carton and the same grid; there is no partial layer, no brick-bonding between layers for stability, and no allowance for stretch-wrap thickness, corner boards, or a slip sheet. If the maximum height isn't an exact multiple of carton height, the leftover space above the last full layer is simply unused.

It does not check pallet weight rating, load overhang beyond the pallet edge, carton crush strength under stacking, or any transport/handling code - treat the result as a starting footprint, not a certified load plan. The presets list common nominal footprints; confirm your actual pallet's dimensions, as real pallets vary by supplier and condition.