Free Pallet Calculator

Preview where shipper labels appear on a pallet before sharing the pattern with your warehouse team. Sign in and open Labels from configuration refinement or Results to place one or two label previews on physical case faces. Adjust label size, rotation and position while inspecting the pallet in 3D. Labels follow each case through upright, tipped and alternating-layer arrangements.

The label exposure panel counts shippers and individual labels separately. A shipper needs at least one fully exposed label; a hidden second label remains included in the individual label counts. Optional shipper colors help locate fully exposed, partly exposed and hidden labels. The geometric assessment measures uncovered label surface open to the outside of the load, including open recesses. It excludes straps, stretch wrap and pallet slat openings and does not guarantee a straight sightline or barcode readability. Applied labels are retained in saved pallet loads, public shares and PDF pallet pattern sheets.

For a simple column layout, divide the usable pallet length and width by the corresponding case dimensions and round each result down. Multiply the two counts to get cases per layer. For repeated equal-height layers, divide the available product height by the placed case height and round down. The height and weight limits can restrict the number of layers or cases.

The calculator searches supported layouts within your selected orientation and overhang constraints, with upright cases as the default. Compare the returned options by total cases, utilization and arrangement; the search does not guarantee a global optimum. Cases per layer × layers gives the total only when every layer has the same count. For a partial or different final layer, use the displayed total and layer breakdown.

TI is the number of cases per layer and HI is the number of layers on the pallet. When all layers have the same count, TI × HI gives the total. For example, 12 cases on each of 5 layers gives 60 cases.

A partial or different final layer needs its own count. Use the displayed total and layer breakdown for these arrangements instead of multiplying the full-layer count by HI. Review those counts together with the selected orientation, pallet dimensions, height and weight limits before sharing warehouse instructions.

Column layouts use a regular grid. Composite layouts combine differently oriented groups of cases within a layer. Pinwheel layouts arrange cases in a rotating pattern within a layer. A Split Block option may also be available. Which layouts appear and how many cases they hold depend on the case dimensions, pallet and selected constraints.

Alternating-layer alignment is a separate option for eligible layouts. Eligible layouts offer repeat, mirror and 180° rotation choices. These change how adjacent layers align where the geometry permits. Where supported and enabled, the calculator can also return repeated full layers with a partial or differently oriented final layer.

Pattern and support indicators describe geometry. They do not certify compression strength, resistance to shifting or transport safety. Review the layer breakdown and support warnings, then assess compression, stability and suitable load securing for the planned conditions.

Footprint utilization compares the case area on a representative layer with the pallet deck area. With overhang it can exceed 100%, so a larger percentage does not necessarily mean a better supported load. Review the actual edge extensions and layer geometry alongside the percentage.

Cube utilization compares total case volume with the available pallet volume, using the pallet footprint and available product height. It helps distinguish unused footprint from unused height. Neither metric is a compression or stability assessment, and neither determines freight class or shipping price.

Overhang occurs when cases extend beyond the pallet edge. It changes the support beneath the cases and can create handling, racking and transport problems. The allowed extension is a planning input, not permission from a customer or carrier.

Set the pallet-edge allowance to match confirmed requirements. A zero allowance keeps case footprints within the deck boundary; it does not establish full base support over deckboard gaps or certify box strength. Review the returned geometry, support warnings and compression assumptions before releasing the load.

Enter the limits for the actual pallet, handling equipment, storage location and transport plan. The height limit includes the pallet deck, and the gross weight limit includes the pallet and cases. The tool uses the entered pallet and case weights when limiting the load. These limits are separate from box compression capacity.

Additional layers increase the load carried by lower cases. Review compression and stability separately, and confirm the entered limits with the responsible site or carrier. A result that fits the entered dimensions and weight is still a planning arrangement.

The pallet arrangement affects the load paths through the cases and the support available to them. Layer count, case weight, alignment, overhang and pallet support all matter. Pattern names alone do not establish the strength of the finished load.

Signed-in users can send the selected pallet arrangement to Load Stability for its supported stability and compression assessments. Use Box Strength separately for its supported compression scenarios. These are planning models, not proof that a load will survive transport. Confirm the actual board and package, environmental conditions, securing method and required physical tests before production or shipment.

The selector provides the following pallet footprints. Use a custom pallet for other dimensions, with its actual deck height and weight. Signed-in users can also reuse saved custom pallet sizes. A footprint preset does not establish a rated load capacity or a permitted loaded height; confirm those limits for the actual pallet and operation.

Use the actual pallet specification and receiving requirements when choosing dimensions. Case footprints that divide a pallet evenly can improve utilization, but dimensional fit alone does not confirm compatibility with a warehouse, handling system or transport route.

Confirm required load height, gross weight, overhang, label placement and securing arrangements with the customer, site and carrier. The linked pallet sizing guide provides additional background; selecting a preset is not a compliance assessment.

Freight density is shipment weight divided by occupied shipping volume. When calculating it separately, include the pallet and use the actual outer shipping envelope, including any load extensions and protective packaging.

The Pallet Calculator reports case counts and utilization; it does not calculate freight density, NMFC class or shipping rates. Use the selected load dimensions and weight with the applicable carrier classification and quoting process to compare costs.