How many boxes fit on a pallet?
Three things decide it: how many boxes fit on one layer, how many layers fit under the height limit, and whether the total stays under the weight limit. Here's how to work it out, and where the quick maths goes wrong.
1. Boxes per layer
Divide the pallet's length and width by the box's footprint and round down. Then try the box turned 90° as well. A UK pallet is 1200×1000 mm and a Euro pallet 1200×800 mm.
For a 600×400 mm carton on a UK pallet:
- Box lengthways: 1200÷600 = 2 across, 1000÷400 = 2 deep, so 4 boxes.
- Box turned: 1200÷400 = 3 across, 1000÷600 = 1 deep, so 3 boxes.
- Mixed: one row of 3 turned boxes (1200×600) plus one row of 2 lengthways (1200×400) fills the full 1000 mm, so 5 boxes.
The simple grid answer (4) wastes a whole box per layer. Mixed patterns like this are where a planner earns its keep.
2. Number of layers
Take the maximum loaded height and subtract the pallet itself (about 144 mm for a standard UK or Euro pallet). Then divide by the box height and round down. With a 1.8 m limit and 300 mm cartons: (1800 − 144) ÷ 300 = 5.5, so 5 layers.
Many carriers price by height too: a half pallet must usually stay under 1.1 m, so stopping a layer or two lower can make delivery cheaper. See pallet delivery costs.
3. Check the weight
Multiply the box count by the box weight and add about 25 kg for a wooden pallet. Compare that with your pallet's and carrier's limit, typically 1000 kg for a full pallet on UK networks. In our example, 25 cartons at 12 kg is 300 kg of goods, well within the limit. With heavy boxes, weight often runs out before space does.
Worked example
| UK pallet 1200×1000 | Euro pallet 1200×800 | |
|---|---|---|
| Carton | 600×400×300 mm, 12 kg | |
| Per layer | 5 (mixed pattern) | 4 |
| Layers (1.8 m limit) | 5 | 5 |
| Cartons per pallet | 25 | 20 |
| Gross weight | ≈ 325 kg | ≈ 265 kg |
When the maths gets harder
Mixed box sizes, drums and canisters that must stay upright, items that can't have anything on top, keeping heavy goods at the bottom, and loads that need several pallets. That's what Pallet Plan is for: add your items and it builds and balances the pallets for you.
More guides: How many boxes fit on a pallet? · UK pallet sizes and weight limits · Pallet delivery costs explained