Length aligned: 6 cartons
3 × 2; pallet 120 × 80 cm
Rotated 90°: 8 cartons
4 × 2; pallet 120 × 80 cm
Compare both uniform layer orientations
Use a 120 × 80 cm pallet with 40 × 30 × 25 cm cartons. With the 40 cm side along the 120 cm deck, three cartons fit along its length and two across its width: six in the layer. Rotate every carton 90 degrees and four fit along the length, two across the width: eight.
The tool draws these two grids to scale. The blank strip in the six-carton drawing is unused deck area. The rotated grid covers the full deck in this particular example. These diagrams compare uniform grids; they do not search interlocking or mixed-orientation patterns.
Account for the pallet itself
The example allows a maximum overall height of 180 cm and uses a 14.4 cm pallet. That leaves 165.6 cm for cartons. Each carton is 25 cm tall, so only six complete layers fit. Seven layers would make the load 189.4 cm tall, above the selected limit.
| Check | Arithmetic | Result |
|---|---|---|
| Aligned layer | floor(120/40) × floor(80/30) | 6 cartons |
| Rotated layer | floor(120/30) × floor(80/40) | 8 cartons |
| Full layers | floor((180 − 14.4)/25) | 6 |
| Carton count | 8 × 6 | 48 |
| Loaded height | 14.4 + 6 × 25 | 164.4 cm |
Read the result as geometry
Forty-eight cartons is the geometric count for these assumptions. It is not permission to stack six layers. The carton supplier must establish stacking strength; the pallet and handling route must support the weight; the load needs suitable restraint and stability. Fragile contents or a no-double-stack instruction can reduce the usable height substantially.
If every carton weighs 12 kg, cartons alone weigh 576 kg. Add the actual pallet, wrap and protection to obtain gross load weight. The current pallet calculator does not enforce a weight limit, so check this separately before treating the count as a shipping plan.
A sensitivity check before preparing a load
Change carton height from 25 to 28 cm. Usable height remains 165.6 cm, but only five layers fit: eight times five gives 40 cartons and an overall height of 154.4 cm. That is why a small increase in box height can remove an entire layer.
Measure the finished load again after wrapping. A bulge or overhang is not represented in these clean rectangles. Container door clearance and warehouse handling rules also remain separate checks.
Reproduce the calculation
Use the related Cargoivo calculator with your own shipment dimensions, weight, or quantity.
Open 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.