GET /api/pallet?pl=120&pw=80&pmh=220&bl=40&bw=30&bh=25What Is Pallet Fitting?
Pallet fitting (also called pallet loading or pallet optimisation) is the process of calculating how many boxes, cartons, or items can be loaded onto a pallet while respecting the pallet's dimensions and weight limits.
Efficient pallet loading reduces shipping costs, minimises wasted space, and ensures cargo stability during transport. A well-packed pallet uses the full footprint and stacks to a safe height without overhanging the pallet edges — overhang increases the risk of damage during handling and can prevent pallets from fitting into racking systems.
How Does the Calculator Work?
The calculator uses a layer-based greedy algorithm — the same method warehouse operatives use when manually building pallet loads. It works in two steps:
Step 1 — One layer: The box footprint (length × width) is tiled across the pallet footprint using simple integer division. If rotation is enabled, both orientations are tried and whichever fits more boxes per layer is chosen.
Step 2 — Stack height: The number of layers is calculated as floor(usable height ÷ box height) where usable height = max stack height − pallet board height. If box weight and max pallet weight are provided, the result is further capped so total weight never exceeds the pallet rating.
Boxes per layer = floor(pallet L ÷ box L) × floor(pallet W ÷ box W)
— repeated for rotated orientation, best wins
Layers = floor((max stack height − pallet board height) ÷ box height)
Total boxes = boxes per layer × layersCommon Pallet Types and Dimensions
FreightUtils includes 15 pallet types with specifications audited against official standards from EPAL, ISO 6780, and IATA.
| Pallet | Dimensions (L×W) | Max Load | Standard | Common Use |
|---|---|---|---|---|
| EUR/EPAL 1 | 1200 × 800 mm | 1,500 kg | EPAL / ISO 6780 | European road freight — most widely used pallet in Europe |
| EUR/EPAL 2 | 1200 × 1000 mm | 1,250 kg | EPAL | UK standard — common in UK retail and distribution |
| EUR/EPAL 3 | 1000 × 1200 mm | 1,250 kg | EPAL / ISO 6780 | Common in FMCG and beverage industries |
| EUR/EPAL 6 (Half) | 800 × 600 mm | 750 kg | EPAL | Retail display, point-of-sale, small consignments |
| GMA (N. American) | 1219 × 1016 mm | 1,089 kg | GMA / ISO | Standard pallet in North America (48×40 inches) |
| CP1 | 1000 × 1200 mm | 1,250 kg | EPAL | Chemical industry standard |
| CP3 | 1140 × 1140 mm | 1,250 kg | EPAL | Chemical drums and IBCs |
| Aircraft PMC | 3175 × 2438 mm | Varies | IATA | Main deck air freight — ULD pallet for wide-body aircraft |
All specifications audited against EPAL, ISO 6780, and IATA official publications. For the complete list of 15 pallet types, use the calculator above.
Calculate by Pallet Type
Select a standard pallet type to open a pre-filled calculator with its exact dimensions.
Pallet Loading Best Practices
- Fill the footprint first. Maximise the pallet area before stacking height. A pallet loaded to 80% area but full height wastes 20% of every layer.
- Interlock layers where possible. Alternating box orientation between layers (brick pattern) improves stack stability and reduces the need for excessive stretch wrapping.
- Respect the pallet edge. Overhang beyond the pallet edge causes damage during forklift handling and prevents pallets from fitting into standard racking (typical beam clearance is designed for flush-loaded pallets).
- Check weight before height. A pallet stacked to maximum height but exceeding the safe working load (SWL) is unsafe. Always check both dimensions.
- Consider the vehicle. Standard European trailers have an internal height of approximately 2.65–2.70m. With a pallet height of 15cm, the maximum cargo height is typically 220cm (including pallet). For containers, check the internal height of the specific container type.
Pallet Dimensions and Vehicle Compatibility
| Vehicle / Container | Internal Width | Internal Height | EUR 1 per row | EUR 2 per row |
|---|---|---|---|---|
| 13.6m Artic Trailer | 2,450 mm | 2,650–2,700 mm | 3 lengthwise or 2 widthwise | 2 widthwise |
| 20ft Container | 2,350 mm | 2,390 mm | 2 widthwise (tight) | 2 widthwise (tight) |
| 40ft Container | 2,350 mm | 2,390 mm | 2 widthwise (tight) | 2 widthwise (tight) |
| 40ft High Cube | 2,350 mm | 2,690 mm | 2 widthwise | 2 widthwise |
Container widths (2,350mm) are tighter than European trailers (2,450mm). Two EUR 1 pallets side by side (2 × 800mm = 1,600mm) fit with clearance, but two EUR 2 pallets (2 × 1,000mm = 2,000mm) leave only 350mm gap — check your specific container.