Mixed-size pallet planning
Mixed box pallet calculator
Combine quantities of different cartons, fill open deck space before stacking and inspect every proposed level in 2D and 3D.
Open the mixed-box planner →Reviewed September 22, 2026Mixed pallets need more than a volume calculation.
Total cubic volume cannot show whether the cartons create a stable, supported footprint. A useful plan must track the position, height and support of each box while respecting the pallet boundary.
Choose the planning priority.
Minimize pallets / freight
Fill available deck positions first, then add boxes to the lowest fully supported columns. This is useful when pallet count and occupied height matter most.
Keep layers simple
Use one carton type per layer. This can be easier to build and inspect, even when it leaves more unused space.
Information that improves the plan.
- Quantity and packed outside dimensions for every box type.
- Maximum load height above the pallet deck.
- Weight of each carton and pallet payload limit.
- Supplier-tested allowable load on top of each carton.
- Required spacing and empty pallet edge.
Read the visual plan from the bottom up.
The plan displays the pallet deck, each stacking level and the 3D result. Verify that each upper carton is supported, that loads stay within declared strength limits and that the final shape can be wrapped and handled safely.
Common questions
Quick answers before you calculate.
Can different box sizes share one pallet?
Yes when they fit within the footprint, height and payload limits and every upper box has adequate support. The final arrangement still requires an operational stability review.
Should heavier boxes go on the bottom?
Usually heavier and stronger boxes should be lower, but weight alone does not prove crush strength. Use supplier-tested allowable top-load values where available.
Is the result a mathematically perfect 3D packing?
No. It is a practical deck-first supported arrangement designed to be understandable and buildable, not a proof of the global optimum.