Free online packaging engineering tool

Free Palletization Calculator

Use KolliPack’s free palletization calculator to calculate boxes per pallet, cartons per layer, total cartons, stack height, pallet weight checks, and pallet utilization. The same page works as a pallet tool, pallet calculator, and pallet pattern calculator for practical packaging engineering decisions.

Use the calculator Open in KolliPack
No account required Ranked pattern alternatives 3D result visualization PDF report
Pallet analysis preview Carton-to-pallet decision support
Best ranked
Cartons/layerCalculated
Total cartonsRanked
UtilizationCompared
Interactive calculator

Calculate your pallet pattern now

Use external carton dimensions in millimetres, select or enter a pallet footprint, and define the maximum carton stack height. KolliPack will rank the available layouts and render the selected result.

This is the same palletization module used inside KolliPack and Packaging Flow. The calculator, result logic, shared UI, 3D rendering, and PDF export are maintained as one implementation.
How to use this tool Inputs, stacking limits, result interpretation, and practical palletization checks.

What the tool does

The Palletization Tool estimates how many identical cartons fit on a pallet footprint and how many layers can be stacked within the allowed height.

Required inputs

  • Carton length, width, and height in mm.
  • Pallet length, width, and height in mm.
  • Max stack height in mm: the finished palletized-load height, including the pallet.
  • Optional carton weight and max bottom-carton load in g.

How to read the result

Total cartons Cartons/layer Layers Pallet floor usage Stack volume usage

The first option is the best ranked result. You can click another result row to redraw a different pallet pattern.

Good engineering practice

  • Use external carton dimensions when checking pallet capacity.
  • Include pallet overhang only when it is explicitly allowed by handling and transport rules.
  • Validate load stability, wrapping, fork handling, and customer-specific restrictions before release.
The 3D view is a clean engineering estimate. Final pallet approval should still consider real carton strength, center of gravity, transport vibration, and warehouse handling.
Carton / Box
Use manual carton dimensions or select a BOX/CRATE from the packaging catalogue. Dimensions are in mm.
Advanced carton parameters
Optional weight and compression settings for bottom-carton load checks.
Show / hide
Optional. Used for the bottom-carton load check.
Optional. Leave empty when no compression limit is known.
Pallet
Use manual pallet dimensions or select a PALLET from the packaging catalogue. Dimensions are in mm.
Default: 150 mm
Advanced parameters
Optional pallet overhang settings.
Result
Recommended pallet layout with practical capacity, height, and load indicators.
Palletization result
Total cartons
50 pcs
Layers
5
Cartons/layer
10
Stack height
1256 mm
Interactive 3D result
Detailed analysis recommended layout, utilization and load check
Recommended palletization
Pallet floor usage: 91.72% | Stack volume usage: 85.09% | Alternate layer possible: Yes | Bottom load check: Not checked
Main layer cartons 10 pcs
Alternate layer cartons 10 pcs
Total palletized-load height 1256.0 mm
Carton arrangement height 1155.0 mm
Pallet floor usage 91.72%
Stack volume usage 85.09%
Bottom-carton load check Not checked
Max bottom-carton load Not available
Bottom-carton load limit Not provided
Validate final stability, wrapping, handling, and customer-specific transport restrictions before release.
Palletization Results
Click a row to redraw another pallet layout. Repeated visible renderings are collapsed into one option.
Option Main layer Alternate layer Layers Total cartons Alternate layer possible Floor usage Volume usage Load check Max bottom load
Option 1 10 10 5 50 Yes 91.72% 85.09% Not checked —
Option 2 9 9 5 45 No 82.55% 76.58% Not checked —
Option 3 9 9 5 45 Yes 82.55% 76.58% Not checked —
Option 4 8 8 5 40 Yes 73.38% 68.07% Not checked —
Option 5 6 6 5 30 Yes 55.03% 51.05% Not checked —
Search-friendly tool names

Pallet tool, pallet calculator, and palletization calculation in one page

Different teams use different names for the same practical need. Some search for a pallet tool, others for a pallet calculator, a palletization calculation, a pallet pattern calculator, or a boxes-per-pallet calculator. KolliPack brings these calculations together in one free online page focused on carton dimensions, pallet dimensions, stack height, pattern alternatives, and utilization.

Pallet calculator

Estimate cartons per layer, number of layers, total cartons per pallet, pallet height, and utilization.

Pallet pattern calculator

Compare practical carton arrangements and review how rotation changes the selected pallet pattern.

Palletization calculation

Turn carton and pallet dimensions into a structured engineering result with visual layout alternatives.

Calculator outputs

What the palletization calculator measures

A good pallet decision is more than a simple “does it fit?” check. KolliPack compares capacity, geometry, utilization, and optional stacking constraints so the result is easier to evaluate.

Cartons per layer

See how many identical cartons fit on the pallet footprint for each ranked layer pattern.

Layers and total cartons

Calculate the number of permitted layers from carton height and maximum stack height, then estimate total pallet quantity.

Space utilization

Compare pallet floor usage and full stack volume usage to identify layouts that reduce unused space.

Alternate layer options

Review whether a different layer orientation can be alternated to support a more interlocked stack concept.

Optional pallet overhang

Add allowed length or width overhang when the packaging, handling equipment, and transport rules permit it.

Bottom-carton load check

Optionally compare the estimated load on the bottom carton with the maximum load value supplied by the user.

How it works

From carton dimensions to a ranked pallet layout

1

Define the carton

Enter the external carton length, width, and height. Optional weight data can support a bottom-load review.

2

Define the pallet and limits

Enter the pallet footprint and maximum carton stack height. Add overhang only when your logistics rules allow it.

3

Compare the results

Review the best-ranked option, inspect the 3D rendering, and select another row to compare an alternative layout.

Worked input example

Example: cartons on a Euro pallet

A quick first analysis can start with a 400 × 300 × 250 mm carton, a 1200 × 800 mm pallet, and a maximum carton stack height of 1500 mm. Enter these values in the calculator to compare the ranked patterns.

Example inputs

Carton400 × 300 × 250 mm
Pallet1200 × 800 mm
Max stack height1500 mm
Overhang0 mm

What to review in the result

  • Whether carton rotation increases cartons per layer.
  • Whether an alternate layer pattern is available.
  • How much pallet floor and stack volume are actually used.
  • Whether the total height complies with the operational limit.
The highest carton quantity is not automatically the safest released pallet. Confirm compression strength, center of gravity, wrapping, handling, and transport stability before implementation.
Pattern interpretation

Regular patterns, mixed orientations, and alternate layers

Cartons can often be arranged in more than one orientation on the same pallet. KolliPack ranks practical layer developments and collapses duplicate visible layouts so you can compare meaningful alternatives instead of reviewing repeated results.

Uniform orientation

Every carton in the layer uses the same footprint orientation. These layouts are simple to understand and often easy to execute.

Mixed-orientation layout

Different footprint orientations can be combined when that improves pallet coverage and produces a practical arrangement.

Alternate layer preview

When available, a related layer can be previewed as an alternate stacking option for a more interlocked pallet concept.

Use cases

Who can use the pallet pattern calculator?

Packaging engineers

Compare carton and pallet alternatives before releasing or changing a packaging instruction.

Logistics teams

Estimate pallet quantity and utilization before reviewing transport loading and freight implications.

Manufacturing and warehousing

Support standardized pallet configurations for handling, storage, line feeding, and outbound operations.

Frequently asked questions

Palletization calculator FAQ

What does a palletization calculator calculate?
It estimates cartons per layer, number of layers, total cartons, pallet floor usage, stack volume usage, and available alternative layer patterns from carton and pallet dimensions.
Is the KolliPack palletization calculator free?
Yes. The public calculator can be used without creating an account during the KolliPack early launch.
Which carton dimensions should I use?
Use the external length, width, and height of the packed carton because those dimensions occupy space on the pallet.
Can the calculator evaluate pallet overhang?
Yes. Optional maximum overhang values can be entered for the pallet length and width directions, but overhang should only be used when handling and transport rules allow it.
Does the result replace physical pallet testing?
No. The result is an engineering estimate. Final approval should still consider carton compression strength, load stability, wrapping, handling, vibration, and customer requirements.
Can I use KolliPack as a pallet calculator?
Yes. KolliPack can be used as a pallet calculator to estimate cartons per layer, number of layers, total cartons per pallet, stack height, and pallet utilization.
What is a pallet pattern calculator?
A pallet pattern calculator compares different carton arrangements on a pallet. KolliPack ranks practical pallet patterns and shows how orientation changes can affect utilization.
What does palletization calculation mean?
Palletization calculation means calculating how cartons or boxes should be arranged on a pallet while considering dimensions, height limits, optional overhang, load checks, stability, and utilization.
Can KolliPack calculate boxes per pallet?
Yes. KolliPack calculates boxes per pallet using carton dimensions, pallet dimensions, maximum stack height, allowed footprint orientation, and selected palletization logic.

Continue from palletization to the full packaging flow

KolliPack connects package selection, palletization, and transport loading so downstream effects can be reviewed in one engineering workflow.

Open Packaging Flow Read the palletization guide