The highest mathematical box count is not automatically a safe pallet load. A usable plan must check the base pattern, permitted height, total weight and the compression strength of the cartons.

Boxes in one layer

For rectangular cartons, compare the two basic orientations:

**A = ⌊pallet length / box length⌋ × ⌊pallet width / box width⌋**

**B = ⌊pallet length / box width⌋ × ⌊pallet width / box length⌋**

Start with the larger result. Mixed rows can occasionally beat either simple grid, so a visual layout check is useful when every position matters.

A standard EPAL Euro pallet measures 1200 × 800 × 144 mm. EPAL states a 1500 kg safe working load when the load is evenly distributed and the pallet is in serviceable condition.

Worked example

Carton: 400 × 300 × 250 mm. Pallet: 1200 × 800 mm.

First orientation:

**⌊1200/400⌋ × ⌊800/300⌋ = 3 × 2 = 6 boxes**

Rotated orientation:

**⌊1200/300⌋ × ⌊800/400⌋ = 4 × 2 = 8 boxes**

The better simple pattern therefore holds 8 boxes per layer.

If the maximum loaded height is 1800 mm, subtract the 144 mm pallet height:

**⌊(1800 − 144) / 250⌋ = 6 layers**

The geometric result is **8 × 6 = 48 boxes**.

Weight may reduce the count

At 18 kg per box, 48 boxes weigh 864 kg. Adding an approximately 25 kg pallet gives a gross pallet weight of about 889 kg.

At 35 kg per box, a full 48-box stack would exceed 1500 kg. The weight-limited count is:

**⌊(permitted pallet load − pallet tare) / gross box weight⌋**

The final quantity is always the lowest count allowed by floor area, height, weight and stability.

What the formula cannot confirm

  • Boxes should not overhang unless the packing plan specifically permits it.
  • Bottom cartons must withstand the compression from every layer above.
  • Fragile goods, liquids and orientation labels may prevent rotation.
  • Slip sheets, corner boards and wrapping increase real dimensions.
  • Pallet capacity does not replace checks for vehicle gross weight and axle load.

Use the EuroTruckTools boxes-per-pallet calculator to compare orientations, layers, loaded height and gross weight. Before dispatch, measure the actual outer carton and confirm the condition and marked capacity of the pallet.