The same cartons, turned a different way, can differ by several cartons per pallet. This article gives you a pallet loading method you can apply directly.
First, remember the pallet size
US standard pallet: 40 × 48 inches, i.e. 101.6 × 121.9 cm.
This is the most common specification in the US. Trucks, overseas warehouses and platform warehouses are all designed around it.
The pallet itself is about 14–15cm high. Do not forget it when calculating total height.
What data the method needs
| Variable | Meaning | Example value |
|---|---|---|
| Pallet length × width | Usable top surface size | 121.9 × 101.6 cm |
| Carton length × width | Two sides of the carton base | 60 × 40 cm |
| Carton height | Determines how many layers | 30 cm |
| Height limit | Maximum total height including pallet | Commonly about 180 cm |
| Weight per carton | Used to calculate total pallet weight | 18 kg |
Step one: how many cartons per layer
Place the two sides of the carton against the two sides of the pallet. First try the straight layout.
Straight layout: 60 along the pallet length 121.9 fits 2 cartons (120cm, 1.9cm left); 40 along the pallet width 101.6 fits 2 cartons (80cm). Per layer 2 × 2 = 4 cartons.
Turn 90° and try: 40 along 121.9 fits 3 cartons (120cm); 60 along 101.6 fits only 1 carton (60cm). Per layer 3 × 1 = 3 cartons.
Take the larger of the two pure layouts: 4 cartons per layer.
Step two: how many layers
Height limit 180cm, minus pallet height 15cm, leaves 165cm.
165 ÷ 30 = 5.5, rounded down to 5 layers.
The margin left is space for stretch film and stacking tolerance. Do not push it to the limit.
Step three: total cartons and total weight
Total cartons = 4 cartons/layer × 5 layers = 20 cartons.
Cargo weight = 20 × 18kg = 360kg. Add the pallet's own weight for the total pallet weight.
For this shipment of 200 cartons, you need 200 ÷ 20 = 10 pallets.
Can mixed layout fit more
Mixed layout: alternate two directions within the same layer to use up the edge margins.
In the example above, the straight layout occupies 120 × 80cm, leaving 21.6cm across the width, which is wasted.
Switch to mixed layout: first place 3 cartons along the length (40cm facing the length, occupying 120 × 60), leaving a strip of 121.9 × 41.6 empty.
In that strip place 2 more cartons (60cm facing the length, occupying 120 × 40), making 5 cartons per layer.
5 cartons/layer × 5 layers = 25 cartons, 200 ÷ 25 = 8 pallets, saving 2 pallets versus the straight layout.
Do not ignore weight limits
There is a maximum total pallet weight, and standards differ by lane and carrier.
Overweight pallets incur extra handling fees at the delivery stage.
Amazon US has a maximum weight of 23kg per carton. Over that, a Team Lift label is required.
Before palletising, confirm the lane's height and weight limits, then decide the number of layers.
Stacking details
Heavy at the bottom, light on top, with the centre of gravity in the middle, to prevent tipping in transit.
When turning cartons 90°, make sure the product orientation inside is consistent, so the goods do not turn over inside.
Stretch film should at least cover the joint between pallet and cargo, plus two strapping bands.
Wooden pallets and Wooden Crate packaging require ISPM 15 treatment, otherwise the US will reject them.
Pallet orientation and forklift operation
The long side of the pallet is usually placed along the direction of the trailer, so forklifts can move in and out smoothly.
Cargo should not extend beyond the pallet edge. Overhang is easily damaged in transit and easily rejected by warehouses.
Pallets in the same shipment should be as uniform in height as possible, for easy stacking and counting.
