The latest articles on DEV Community by minh clan2 (@minh_clan2_47f73b75c2bfce). https://dev.to/minh_clan2_47f73b75c2bfce https://media2.dev.to/dynamic/image/width=90,height=90,fit=cover,gravity=auto,format=auto/https:%2F%2Fdev-to-uploads.s3.us-east-2.amazonaws.com%2Fuploads%2Fuser%2Fprofile_image%2F4222501%2F4cfd616b-1e3a-4cd1-a303-204b0e6cfbd2.png https://dev.to/minh_clan2_47f73b75c2bfce en minh clan2 Mon, 02 Nov 2026 13:47:15 +0000 https://dev.to/minh_clan2_47f73b75c2bfce/how-to-calculate-how-many-cartons-fit-on-a-pallet-with-a-worked-example-bbc https://dev.to/minh_clan2_47f73b75c2bfce/how-to-calculate-how-many-cartons-fit-on-a-pallet-with-a-worked-example-bbc <p>Working out how many cartons fit on a pallet is mostly division, and a bit of care about orientation. Here is the method I use.</p> <h2> Variables </h2> <p>Pallet footprint L × W, carton footprint l × w, carton height h, pallet deck height d, height limit H.</p> <h2> 1. Cartons per layer </h2> <p>Compute <code>floor(L ÷ l) × floor(W ÷ w)</code> for the carton as is, then again with the carton turned 90° (<code>floor(L ÷ w) × floor(W ÷ l)</code>). Keep the larger result.</p> <p>An upper bound is <code>floor(L × W ÷ (l × w))</code>. If your result is lower, a mixed pattern may recover one or two cartons.</p> <h2> 2. Layers </h2> <p><code>floor((H − d) ÷ h)</code></p> <h2> 3. Total </h2> <p>Total = cartons per layer × layers.</p> <h2> 4. Check weight and overhang </h2> <p>Total weight must stay under the pallet's rating, and cartons should not hang over the edges.</p> <h2> Worked example (EUR pallet) </h2> <p>Pallet 1200 × 800 mm, deck 144 mm, height limit 1650 mm, carton 300 × 200 × 150 mm.</p> <ul> <li>Layout: 1200 ÷ 300 = 4 and 800 ÷ 200 = 4, so 16 per layer. The upper bound is 960,000 ÷ 60,000 = 16, so this is a perfect fit.</li> <li>Layers: (1650 − 144) ÷ 150 = 10.04, so 10 layers, which is 1,644 mm in total.</li> <li>Total: 16 × 10 = 160 cartons. At 5 kg each that is 800 kg.</li> </ul> <h2> Practical tips </h2> <p>Interlocking layers (rotating alternate layers) hold better than straight columns but can waste a little space. Check the bottom carton's compression strength, and check carrier height limits.</p> <h2> Disclosure </h2> <p>I built a free calculator that tries these patterns for you and shows a 3D preview, with US GMA (48×40"), EU (1200×800 mm) and custom pallet sizes: <a href="https://app.maximumcarton.com/?utm_source=devto&amp;utm_medium=community&amp;utm_campaign=backlinks" rel="noopener noreferrer">Maximum Carton</a></p> logistics warehouse supplychain tutorial