How many boxes fit on a 48 × 40 pallet?

It depends on the box footprint and orientation. The calculator tries column stacks in both orientations and two-block mixed patterns, then multiplies the best layer by the number of layers your height and weight limits allow. A 16 × 12 inch box gives 10 per layer with a mixed pattern but only 9 in a plain column stack.

Should I use a column stack or an interlocking pattern?

Column stacking (boxes directly on top of each other) is strongest because the box corners carry the load. Mixed or interlocked patterns fit more per layer and resist shifting, but put some boxes over gaps. For heavy or fragile cases keep columns; for light, sturdy cartons the mixed pattern usually wins.

What height and weight limits should I use?

Use the limit of the strictest link in the chain: the carrier, the receiving warehouse and your own racking. Amazon FBA inbound pallets, for example, are limited in height and weight per pallet; many LTL carriers price above a height threshold. The calculator lets you set both and shows which one binds.

Usually not. Boxes that hang over the deck get crushed and are refused by many receivers. Leave overhang at 0 unless the recipient has told you otherwise.

Pallet Calculator

Work out how many cartons fit on a pallet. The planner compares column stacks and two-block mixed patterns in both orientations, applies your height and weight limits, and draws the winning layer so you can build it on the floor.

Pallet

Standard

Allowed overhang per side

Most carriers and retailers want 0

Pallet length

Pallet width

Max stack height incl. pallet

Amazon FBA inbound: 72 in; many LTL carriers: 96 in

Max load weight

Excluding the pallet itself

Box

Box length

Box width

Box height

Box weight

Result

Boxes per pallet

Per layer

10 (Mixed (two blocks along width))

Layers

height allows 5, weight allows 13

Load

55.5 in · 750 lb

100% of the deck used

One layer, top-down. Dashed line is the pallet footprint plus any overhang you allowed.

Other patterns: Mixed (two blocks along width, rotated) 10 · Column (length along length) 9 · Mixed (two blocks along length) 9 · Mixed (two blocks along length, rotated) 9 · Column (rotated 90°) 8

Pallet sizes the calculator knows

Standard	Deck (inches)	Used in
GMA / North America 48 × 40 in	48.0 × 40.0	US/CA
EUR / EPAL 1200 × 800 mm (47.2 × 31.5 in)	47.2 × 31.5	EU
UK standard 1200 × 1000 mm (47.2 × 39.4 in)	47.2 × 39.4	UK
Australian standard 1165 × 1165 mm (45.9 × 45.9 in)	45.9 × 45.9	AU
Half pallet 48 × 20 in	48.0 × 20.0	US

How the layer is planned

The planner tests four families of layouts: every box the same way round (two orientations) and two-block patterns where one block runs one way and the remaining strip runs the other way, split along either axis. It keeps the layout with the most boxes. Layers are limited by the lower of two counts: how many box heights fit under your maximum stack height once the pallet deck is subtracted, and how many full layers stay under your maximum load weight.

Worked example

16 × 12 × 10 inch cartons weighing 15 lb on a 48 × 40 GMA pallet with a 60 inch height limit and a 2,000 lb load limit: a column stack fits 3 × 3 = 9 per layer, but a two-block pattern fits 10 (four cartons turned sideways along one edge plus six the other way). Height allows five layers of 10 inches on a 5.5 inch deck; weight allows 13 layers of 150 lb; so five layers and 50 cartons at 55.5 inches and 750 lb.

Stacking tips that keep the load intact

Heaviest cartons on the bottom; never let a lighter layer carry a heavier one.
Keep cartons flush with the edge; overhang is the most common reason a pallet is refused.
Wrap from the deck up, catching the pallet in the first wraps so the load and the pallet move as one piece.
Use a slip sheet or corner boards when mixed patterns leave cartons over gaps.

Questions sellers ask

How many boxes fit on a 48 × 40 pallet?: It depends on the box footprint and orientation. The calculator tries column stacks in both orientations and two-block mixed patterns, then multiplies the best layer by the number of layers your height and weight limits allow. A 16 × 12 inch box gives 10 per layer with a mixed pattern but only 9 in a plain column stack.
Should I use a column stack or an interlocking pattern?: Column stacking (boxes directly on top of each other) is strongest because the box corners carry the load. Mixed or interlocked patterns fit more per layer and resist shifting, but put some boxes over gaps. For heavy or fragile cases keep columns; for light, sturdy cartons the mixed pattern usually wins.
What height and weight limits should I use?: Use the limit of the strictest link in the chain: the carrier, the receiving warehouse and your own racking. Amazon FBA inbound pallets, for example, are limited in height and weight per pallet; many LTL carriers price above a height threshold. The calculator lets you set both and shows which one binds.
Is overhang allowed?: Usually not. Boxes that hang over the deck get crushed and are refused by many receivers. Leave overhang at 0 unless the recipient has told you otherwise.