Pallet Calculator
Work out how many cases fit on a pallet: enter usable pallet and case dimensions to get cases per layer, layers, total cases, volume utilisation, and the cube-method theoretical maximum.
How many cases fit on a pallet? This tool answers it two ways: a layer-fit estimate that stacks whole cases in a single orientation (the conservative number you can actually build), and a cube-method figure that divides pallet volume by case volume (the theoretical ceiling). The gap between them shows how much a smarter stacking pattern could recover.
How it works
Enter the usable pallet dimensions — the loadable deck footprint and the maximum stack height after clearances — and the outer case dimensions. The layer-fit method floors each division: whole cases along the length times whole cases along the width gives cases per layer, whole case-heights within the stack height gives layers, and the product is cases per pallet. The cube method simply divides total pallet volume by case volume. Volume utilisation shows how much of the cube the layer-fit load actually uses.
The formula
Cases per layer = floor(PL / CL) x floor(PW / CW). Layers = floor(PH / CH). Cases = cases per layer x layers. Utilisation % = 100 x cases x case volume / pallet volume. Cube-method cases = (PL x PW x PH) / (CL x CW x CH) — a pure volume ratio that ignores stacking geometry.
Worked example
A 48 x 40 in pallet with 60 in of usable height and 16 x 12 x 10 in cases: floor(48/16) x floor(40/12) = 3 x 3 = 9 cases per layer; floor(60/10) = 6 layers; 9 x 6 = 54 cases at 90% volume utilisation. The cube method gives 115,200 / 1,920 = 60 cases — the 6-case gap is space a single-orientation pattern cannot reach.
Frequently asked questions
Why do the two case counts differ?
The layer-fit count only stacks whole cases in one orientation, so leftover strips along the pallet edges go unused. The cube-method count assumes every cubic inch is usable, which no real pattern achieves. The truth is usually between the two: rotating cases or mixing orientations within a layer (pinwheeling) can beat the single-orientation number but never the cube ceiling.
What pallet size should I enter?
Enter the usable load dimensions, not the nominal pallet size. A standard GMA pallet is 48 x 40 in, but if your cases may not overhang, that is also your footprint limit. For height, start from the constraint — truck door, container, or racking opening — subtract the pallet's own height (about 5-6 in for GMA) and any clearance, and enter what is left.
Does this account for weight limits or stacking strength?
No. It is a pure dimensional fit: it ignores pallet and vehicle weight caps, case crush strength, load stability, and overhang rules. A 54-case dimensional fit can still be an illegal or uncrushable load, so check weight and compression limits before finalising a pallet spec.
Can I use centimetres instead of inches?
Yes — the math is unit-agnostic as long as all six dimensions use the same unit. Enter everything in centimetres and the case counts and utilisation percentage are unchanged; only the volumes behind them change units.
Related tools
This is a planning estimate. Results depend on your inputs and assumptions; confirm against your own data before ordering.
- All cases are identical and loaded in a single orientation (case length along pallet length).
- Cases stack in full columns; no interlocking, pinwheel, or mixed-layer patterns.
- Cases stay within the pallet footprint — no overhang.
- All cases are identical.
- Volume is perfectly divisible — every cubic inch of pallet cube is usable.