From the factory door to the first warehouse · Cartons, decks and limits
Pallet loading and pallet limits
A pallet is limited by deck footprint, cargo height and gross weight. The footprint sets the layer count; height and weight set how many layers survive.
Key facts
| ISO pallet | 1200 × 1000 mm — common in Asia and general export trade |
|---|---|
| EUR/EPAL pallet | 1200 × 800 mm — common in European road and retail supply chains |
| GMA pallet | 1219 × 1016 mm (48 × 40 in) — common in North American grocery and retail |
| Road height | Often 1.6–1.8 m total including the pallet; air and parcel networks are lower |
| Road weight | Often 1000–1200 kg gross per pallet; check the carrier and local rules |
| Overhang | Not allowed in this model; overhanging cartons crush and can be refused |
The deck decides the layer count
Cartons per layer is a footprint problem. Try both ways of turning the carton on the deck and keep the orientation that fits more. A 50 × 40 cm carton on a 120 × 100 cm pallet fits four per layer one way and six the other, a 50 per cent difference from the same carton.
Keep cartons upright unless the product and packaging allow otherwise. Laying cartons down can gain layers but may break stacking strength, leak liquids or void the packaging warranty.
Height and weight caps arrive later
Layers are limited by the cargo height allowance and by how well the stack holds. The pallet weight limit then caps the cartons regardless of geometry. Dense cargo often hits the weight limit with the pallet only half full, while light bulky cartons hit the height limit first.
Stretch wrap, corner boards, strapping and a top sheet add a few centimetres and a little weight; they also make the load stable enough to survive the journey. A pallet that is cheap on paper but arrives crushed is not cheap.
Pallet count is a freight decision
Once cartons per pallet are known, the shipment quantity converts into pallets. The last pallet is usually the expensive one: freight may be charged per pallet, per lane or per cubic metre, so a nearly empty final pallet can destroy the unit economics.
Compare palletised and floor-loaded options for full containers. Pallets make handling faster and reduce damage but consume cubic space; LCL is normally billed on volume, so the pallet count matters less there than on a per-pallet road service.
Frequently asked questions
How many cartons fit on a pallet?
It depends on the carton footprint and the height limit. A 50 × 40 × 30 cm carton on a 120 × 100 cm pallet fits six per layer and, with 150 cm of cargo height, five layers: 30 cartons before efficiency and weight limits.
Should the pallet itself count toward the height limit?
Yes when checking clearance. The calculator asks for cargo height above the pallet; add the pallet height, usually 12–15 cm, to compare with a trailer, container or rack limit.
Can pallets be stacked on top of each other?
Only if the cartons and packaging are rated for it. Double-stacking doubles the load on the bottom pallet and can exceed racking or floor limits. Many warehouses refuse stacked pallets for crushable goods.
Why does the pallet count matter for freight?
Per-pallet road rates and handling charges scale with pallet count, and a half-empty last pallet pays the same as a full one. For full containers, pallets also waste cubic space compared with floor loading.
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