Overall height includes the pallet
If a warehouse allows a 160 cm maximum loaded height, the cargo does not receive all 160 cm. Subtract the pallet deck height first, then divide the remaining vertical space by carton height.
For example, with a 14.4 cm pallet and 28 cm cartons, usable cargo height is 145.6 cm. Five complete layers use 140 cm, while a sixth would exceed the limit.
Leave operational tolerance
Real pallets and cartons vary. Compression, bulging, slip sheets and top protection can add height. A plan that lands exactly on the maximum may fail measurement at the dock.
Define a reasonable internal tolerance based on your packaging process rather than forcing every theoretical millimeter into the load.
Height interacts with stability
A taller pallet can increase cube utilization while making handling less stable. Center of gravity, carton strength, pallet quality and load restraint all need to support the chosen stack.
Confirm warehouse rack clearances, vehicle interior height and customer receiving limits before making a taller pattern standard.
Include top protection before counting layers
For a 160 cm overall limit, 14.4 cm pallet and 28 cm cartons, five layers produce 154.4 cm before top protection. A fictional 6 cm allowance for a top cap and process clearance leaves only 139.6 cm for cartons, so four complete layers fit. The 6 cm figure is an explicit scenario assumption, not a recommended universal safety margin.
To reproduce the scenario in the current tool, enter a 154 cm maximum overall height (160 − 6), retain the 14.4 cm deck and use 28 cm carton height. Record the allowance separately so someone does not mistake 154 cm for the receiving limit.
| Allowance above the stack | Usable carton height | Complete layers |
|---|---|---|
| 0 cm | 145.6 cm | 5 |
| 6 cm | 139.6 cm | 4 |
Reproduce the calculation
Use the related Cargoivo calculator with your own shipment dimensions, weight, or quantity.
Open Cartons Per Pallet Calculator →Cargoivo provides educational planning information, not a freight quote, engineering approval, customs advice, or carrier commitment. Verify current service rules, equipment specifications, and commercial terms before shipping.