Pallet Loading Basics: Footprint, Height and Weight

Start with the actual pallet

Record the pallet’s length, width and height, then establish the limits for the loaded handling unit. Reference pallet types are a useful starting point, but the assigned pallet’s condition and permitted use still matter.

The EPAL Euro reference footprint is 1200 × 800 mm with a height of 144 mm. EPAL 2 uses 1200 × 1000 mm with a height of 162 mm. Their published working-load figures differ; our pallet resource links the source records rather than treating every pallet as interchangeable.

Keep cargo height separate

If a receiving warehouse permits a total loaded height of 1,500 mm and the pallet is 144 mm high, the nominal height left above the pallet is 1,356 mm before any additional allowance. Enter that cargo-height limit in the pallet calculator.

Do not enter the total loaded height as cargo height or subtract pallet height twice. Stretch wrap, top protection, pallet variation and a practical clearance allowance can further change what is usable.

Count whole cartons on each axis

For one orientation, divide pallet length by carton length and pallet width by carton width, rounding both down. Multiply the two counts to get cartons per layer. Then divide available cargo height by oriented carton height and round down for layers.

A 120 × 80 cm footprint with 40 × 30 × 20 cm cartons and 100 cm cargo height allows a 3 × 2 footprint and five layers in one orientation: 30 cartons. Rotating to 40 × 20 × 30 cm gives 3 × 4 positions and three layers: 36 cartons, the best tested uniform layout. Changing the vertical edge changes both footprint and layer count.

Apply the weight constraint

If those cartons weigh 10 kg each, the 36-carton layout would contain 360 kg of cargo. A chosen maximum cargo payload of 250 kg permits only 25 cartons even though 36 positions fit geometrically.

Use a payload appropriate to the pallet, handling method and operating conditions. The pallet’s self-weight is separate from the cargo payload input. A floor, rack or transport limit may introduce a different constraint that this simple calculator does not evaluate.

A fit count is not a stacking approval

The model tests identical cartons in one uniform orientation. It does not evaluate carton compression, stability, load distribution, alternate-layer interlocking or the adequacy of restraint. A carton that geometrically fits on its side may still be prohibited from traveling that way.

Use the estimate to compare possible pack dimensions and quantities. Before handling or transport, confirm permissible orientation, pallet suitability and the loaded arrangement with the responsible warehouse or logistics provider.

• Avoid using product dimensions instead of packed carton dimensions.
• Do not assume that a geometrically possible rotation is allowed.
• Do not assume a pallet reference load applies to every support condition.
• Include the pallet when later measuring total loaded shipment volume.