What is the most common US pallet size?

The most common US footprint is 48 by 40 inches. Actual pallet specifications and usable deck dimensions must still be verified.

Can the planner estimate mixed-size orders?

Yes. The mixed-size mode fills the pallet deck first and then builds fully supported columns from declared quantities, dimensions, height and optional weight limits. It is a practical estimate, not a certified or mathematically optimal 3D load plan.

PPallet Fit Pro

Free pallet calculator

How many boxes fit on your pallet?

Enter your box’s outside size. See the fit and your actual order instantly—no account needed.

Start here

What are you loading?

Enter your measurementsThe footprint determines boxes per layer. The heights determine how many complete layers fit.

Enter the size of one box or item

Measure the outside edges, including packaging and anything that sticks out.

Box or item length (in)Box or item width (in)Box or item height (in)

Check your pallet size

We start with the common 48 × 40 in US pallet. Change it if yours differs.

48 × 40 in

Pallet length (in)Pallet width (in)

Using another pallet? Replace the length and width above. The result updates automatically.

Set the pallet and load height

Enter the pallet base height and the maximum total height, including pallet and load.

Pallet base height (in)Maximum total height (in)

Confirm the height limit with your carrier and receiving site.

Example maximum capacity50 boxes per pallet

Your 4-box order needs 1 pallet. The drawing shows the boxes actually loaded; weight not checked.

Enter your order quantity

The drawings show the actual boxes on the pallet and update as you type.

Total boxes or items

Optional spacing and weight limits

Leave spacing and empty edge at zero when boxes can touch and the full pallet surface is usable.

Space between items (in)Empty edge around pallet (in)Weight of each packed box (lb, optional)Maximum box payload on pallet (lb, optional)

Enter both weight values to cap the box count. Payload excludes the pallet itself. Confirm its rating with your pallet supplier and carrier; this does not check box stacking strength.

Pallet Fit Pro · planning briefUnited States

Example maximum capacity · change the measurements

50boxes or items
per pallet

Your order: 4 boxes → 1 pallet. The drawing shows your 4 loaded boxes, not all 50 possible positions.

10 positions per layer × 5 possible height layers = 50 by dimensions. Weight not checked. Confirm stacking strength and stability separately.

Top layer on the pallet

4 of 10 available positions are used.

4 of 10 positions used · two orientations in one layer

Actual pallet in 3D

4 boxes across 1 layer; only loaded boxes are drawn.

View 1 of 4

4 boxes on shown pallet1 of 5 possible layers used4 of 10 top-layer positions used18 in shown pallet height66 in available load height6 in pallet base

See how this estimate was calculated

2 orientationsin two adjacent blocks

100%pallet surface used

Mixed orientationsshown direction

0.00sq ft left uncovered

Three simple layouts comparedSame box, spacing and edge clearance

Lengthwise93 across × 3 down · 90% used

Turned 90°84 across × 2 down · 80% used

Two orientations in one layerChosen10Two adjacent rectangular blocks · 100% used

The planner also checks simple two-block mixed layouts. The drawing shows the chosen positions; this is not a guaranteed optimal packing or a load-safety certification.

Your full order

4 boxes using footprint, height and declared weight limits

1estimated pallet50 maximum per pallet · drawing shows 4 boxes

The drawing above represents the pallet, including a partial top layer. The final quantity may be lower because of unverified box strength, stability or operating limits. Weight is only checked when both optional weight values are entered.

Before you load the palletConfirm weight, stacking strength, stability, overhang, equipment limits and receiving requirements.

Measurements used

Pallet: 48 × 40 × 6 in
Box or item: 16 × 12 × 12 in
Boxes on shown pallet: 4
Shown pallet height: 18 in
Entered total limit: 72 in
Between items: 0 in
Empty edge: 0 in on each side
Layout: Mixed orientations · two blocks
Weight of each box: Not entered
Box-payload limit: Not entered
Declared box weight on shown pallet: Unknown

The 3D view helps you understand dimensions; it does not prove that the load is stable or safe. It checks only the declared box weight against the declared box-payload limit when both are entered. It does not evaluate pallet tare, compression, mass distribution, securement, door clearance or regulatory compliance.

Different box sizes

Plan a mixed order visually.

Add the quantity and size of each box, then choose whether to minimize freight or keep every layer simple.

Box-by-box drawingsEvery estimated layer shows where each carton sits on the pallet.

Set the pallet limits

Use the available top surface. Load height is measured above the pallet deck; pallet height is excluded.

Pallet length (in)Pallet width (in)Maximum load height (in)

What do you want to optimize?

Optional spacing and weight limits

Space between boxes (in)Empty edge (in)Maximum box payload (lb)

The payload is the allowed box weight and excludes the pallet itself. Add each box weight so the planner can prefer heavier boxes on the pallet deck. Leave the payload limit at zero if unknown.

Add every box size

Enter packed outside dimensions and the quantity needed.

Box name

QuantityLength (in)Width (in)Height (in)

Weight and stacking limits (optional)

Weight each (lb)Allowed load on top (lb)

Use a tested allowable top load from your box supplier, not the shipping weight printed on a box certificate.

Box name

QuantityLength (in)Width (in)Height (in)

Weight and stacking limits (optional)

Weight each (lb)Allowed load on top (lb)

Use a tested allowable top load from your box supplier, not the shipping weight printed on a box certificate.

Example with starting values1 pallet

10 of 10 boxes placed. See the visual plan below.

Weight and stacking strength are not fully checked.

Pallet Fit ProMixed-box visual loading plan

United States

Example estimate · change the measurements

1estimated
pallet

10 of 10 boxes are included in this supported loading plan.

Deck-first geometric support applied; strength not fully checkedThe planner fills open pallet-floor positions before stacking. Every upper box then sits within one box below. Enter each box weight and its tested allowable top load to check compression limits.

The 3D drawing shows the whole pallet. The first drawing is the pallet deck; later drawings show boxes added at each height. Build the columns from the deck upward and never bridge an unsupported gap.

Pallet 110 boxes · 10 / 60 in high

1 stacking level belowDeck-first, supported column placement

3D pallet viewBox height, footprint and level position are drawn proportionally.

Box A: 16 × 12 × 10 inBox B: 12 × 10 × 8 in

View 1 of 4

10 boxes shown separately1 stacking level10 in occupied height81.2% pallet deck used

Pallet deck · 10 Mixed boxesstarts at 0 in
Box ABox ABox ABox ABox ABox BBox BBox BBox BBox B
Mixed-size floor plan5 × Box A: 16 × 12 × 10 in5 × Box B: 12 × 10 × 8 in

What this plan optimizesEvery entered box already fits on one pallet, so the pallet count cannot be reduced below this. The planner fills the pallet deck before stacking, then adds each next box to the lowest fully supported column. Boxes at the same height slide within their supporting footprint to form tighter blocks. It is a practical planning arrangement, not a mathematical proof of the globally best 3D packing.

Compression is checked only when both box weight and a supplier-tested allowable top load are entered. Humidity, storage time, stacking pattern, box condition, contents and handling can reduce real strength; verify the final load operationally.

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Pallet size quick reference

Compare common pallet footprints.

Counts below use the box currently entered in your same-size planner. Confirm the real pallet dimensions before loading.

PalletDimensionsSame-size box fitTypical use

US standardNWPCA + CHEP48 × 40 in10 itemsMost common US footprint

North American half palletCHEP40 × 24 in4 itemsStore display and replenishment

1200 × 1000 referenceISO 6780 + CHEP47.24 × 39.37 in8 itemsInternational reference; verify receiver

1200 × 800 referenceISO 6780 + CHEP47.24 × 31.50 in5 itemsEuro-format reference; not US standard

Return without an account

Your saved same-size setups stay on this device.

Save up to five same-size configurations. Nothing is sent to a Pallet Fit Pro account.

No saved same-size setups yet. Use “Save this setup” in the same-size planner.

Use the result safely

Turn the estimate into a real loading plan.

Confirm the palletUse the size guide as a starting point, then measure the usable top surface.
Measure the packed itemInclude the box, wrapping, handles and anything that extends beyond the product.
Leave needed spaceAdd separation between items and an empty edge only when your operation requires them.
Check before loadingUse the drawing as a planning aid, then verify weight, stability and receiving requirements.

Source-led reference

Dimensions are useful only with context.

NWPCA identifies the 48 × 40 inch footprint as the most common in the United States. CHEP publishes specifications for its 48 × 40 inch full pallet and 40 × 24 inch half pallet. ISO 6780 covers principal dimensions and tolerances for flat pallets used in intercontinental materials handling.

Sources reviewed September 2026. Verify current supplier and receiver requirements before operational use.

Pallet planning guides

Learn the method behind the result.

Use the calculator immediately or review the guide that matches your shipment.

How many boxes fit?From boxes per layer to the final pallet count.48 × 40 pallet calculatorPlan on the most common US footprint.Mixed box pallet plannerCombine different carton sizes with visible support.TI-HI calculatorUnderstand cases per layer and layers high.

Pallet-size questions

Fast answers, with clear limits.

What is the most common pallet size in the United States?

The 48 × 40 inch footprint is the most common US size in the cited NWPCA and CHEP material. That does not mean every pallet or receiving network uses it.

How many boxes fit on a 48 × 40 pallet?

It depends on the outside box size, direction, spacing and empty edge. Enter those values above to see a simple layout and estimated count.

Can I plan an order with different box sizes?

Yes. Choose “Several box sizes,” enter each size and quantity, and select whether to minimize pallets or keep uniform layers. Every estimated layer includes a box-level drawing.

Does this calculate pallet weight or stacking height?

Both modes use the declared box heights. In the same-size mode, enter the packed-box weight and allowed box payload to cap the count; the mixed-size mode can also respect a payload limit. Neither mode verifies box strength, stability, securement or regulatory compliance.

Which mixed-size priority should I choose?

Choose “Minimize pallets / freight” to mix sizes on the same floor plan when they fit. Choose “Keep layers simple” when easier building and inspection are more important than maximum space use.

Are saved and shared plans private?

Saved plans remain in this browser. Shared links contain only measurements, optional weight limits, display unit and order quantity—never a name, email or address.