{
  "slug": "pallet-load-optimizer",
  "title": "Pallet Load Calculator",
  "heading": "Pallet Load Calculator",
  "category": "other",
  "url": "https://www.revenuelab.fyi/toolbox/pallet-load-optimizer",
  "summary": "Cases per layer, layers per pallet, and total units shipped.",
  "description": "Fit cases onto a standard pallet footprint two ways — lengthwise and rotated — take the better result, then stack to your maximum height and weight limit to see the real pallet quantity.",
  "formula": "Cases per layer = best of both orientations; layers = min(height limit, weight limit).",
  "dateModified": "2026-09-30",
  "run_url": "https://www.revenuelab.fyi/api/public/calc?tool=pallet-load-optimizer",
  "inputs": [
    {
      "id": "palletL",
      "label": "Pallet length",
      "kind": "number",
      "hint": null,
      "default": 48,
      "unit": "in",
      "min": 12,
      "max": null
    },
    {
      "id": "palletW",
      "label": "Pallet width",
      "kind": "number",
      "hint": null,
      "default": 40,
      "unit": "in",
      "min": 12,
      "max": null
    },
    {
      "id": "maxHeight",
      "label": "Max stack height (incl. pallet)",
      "kind": "number",
      "hint": null,
      "default": 60,
      "unit": "in",
      "min": 12,
      "max": null
    },
    {
      "id": "deckHeight",
      "label": "Pallet deck height",
      "kind": "number",
      "hint": null,
      "default": 5.5,
      "unit": "in",
      "min": 0,
      "max": null
    },
    {
      "id": "caseL",
      "label": "Case length",
      "kind": "number",
      "hint": null,
      "default": 16,
      "unit": "in",
      "min": 1,
      "max": null
    },
    {
      "id": "caseW",
      "label": "Case width",
      "kind": "number",
      "hint": null,
      "default": 12,
      "unit": "in",
      "min": 1,
      "max": null
    },
    {
      "id": "caseH",
      "label": "Case height",
      "kind": "number",
      "hint": null,
      "default": 10,
      "unit": "in",
      "min": 1,
      "max": null
    },
    {
      "id": "caseWeight",
      "label": "Case weight",
      "kind": "number",
      "hint": null,
      "default": 22,
      "unit": "lb",
      "min": 0,
      "max": null
    },
    {
      "id": "maxWeight",
      "label": "Max pallet weight",
      "kind": "number",
      "hint": null,
      "default": 2000,
      "unit": "lb",
      "min": 1,
      "max": null
    },
    {
      "id": "unitsPerCase",
      "label": "Units per case",
      "kind": "number",
      "hint": null,
      "default": 12,
      "unit": null,
      "min": 1,
      "max": null
    }
  ],
  "outputs": [
    {
      "id": "cases",
      "label": "Cases per pallet",
      "format": "number",
      "hint": null,
      "primary": true
    },
    {
      "id": "perLayer",
      "label": "Cases per layer",
      "format": "number",
      "hint": null,
      "primary": false
    },
    {
      "id": "layers",
      "label": "Layers high",
      "format": "number",
      "hint": null,
      "primary": false
    },
    {
      "id": "units",
      "label": "Units per pallet",
      "format": "number",
      "hint": null,
      "primary": false
    },
    {
      "id": "weight",
      "label": "Loaded weight (lb)",
      "format": "number",
      "hint": null,
      "primary": false
    }
  ],
  "worked_example": {
    "inputs": [
      "Pallet length: 48 in",
      "Pallet width: 40 in",
      "Max stack height (incl. pallet): 60 in",
      "Pallet deck height: 5.5 in",
      "Case length: 16 in",
      "Case width: 12 in",
      "Case height: 10 in",
      "Case weight: 22 lb",
      "Max pallet weight: 2000 lb",
      "Units per case: 12"
    ],
    "outputs": [
      "Cases per pallet: 45",
      "Cases per layer: 9",
      "Layers high: 5",
      "Units per pallet: 540",
      "Loaded weight (lb): 990"
    ]
  },
  "how_to": {
    "title": "How to use this",
    "steps": [
      "Enter pallet length (in).",
      "Enter pallet width (in).",
      "Enter max stack height (incl. pallet) (in).",
      "Enter pallet deck height (in).",
      "Enter case length (in).",
      "Enter case width (in).",
      "Enter case height (in).",
      "Enter case weight (lb).",
      "Enter max pallet weight (lb).",
      "Enter units per case.",
      "Read your cases per pallet on the right — it updates as you type.",
      "Hit Share to keep the scenario or send it to someone."
    ]
  },
  "scenarios": [
    {
      "name": "Conservative",
      "description": "Lower-end numbers — what if things land soft?",
      "values": {
        "palletL": 29,
        "palletW": 24,
        "maxHeight": 36,
        "deckHeight": 3.3,
        "caseL": 9.6,
        "caseW": 7.199999999999999,
        "caseH": 6,
        "caseWeight": 13,
        "maxWeight": 1200,
        "unitsPerCase": 7
      }
    },
    {
      "name": "Typical",
      "description": "Defaults — the most common real-world setup.",
      "values": {
        "palletL": 48,
        "palletW": 40,
        "maxHeight": 60,
        "deckHeight": 5.5,
        "caseL": 16,
        "caseW": 12,
        "caseH": 10,
        "caseWeight": 22,
        "maxWeight": 2000,
        "unitsPerCase": 12
      }
    },
    {
      "name": "Ambitious",
      "description": "Higher-end numbers — what if things really pop?",
      "values": {
        "palletL": 77,
        "palletW": 64,
        "maxHeight": 96,
        "deckHeight": 8.8,
        "caseL": 25.6,
        "caseW": 19.200000000000003,
        "caseH": 16,
        "caseWeight": 35,
        "maxWeight": 3200,
        "unitsPerCase": 19
      }
    }
  ],
  "limitations": [
    "Estimates assume standard, average conditions — local rules, pricing, and materials vary.",
    "Results are rounded for readability; add a buffer before ordering, booking, or committing.",
    "Double-check anything with a real cost attached against a local quote."
  ],
  "faq": [
    {
      "q": "Why does rotating the case matter?",
      "a": "A 16×12 case fits 10 per layer one way and 9 the other on a 48×40 pallet. Choosing the better orientation adds a full case per layer, which compounds across the stack."
    },
    {
      "q": "What height do warehouses allow?",
      "a": "48 to 60 inches including the pallet is common for floor-loaded trailers, and many retailers cap inbound pallets at 50 or 52 inches."
    }
  ],
  "related": [],
  "license": "CC-BY-4.0",
  "citation": "RevenueLab — Pallet Load Calculator (https://www.revenuelab.fyi/toolbox/pallet-load-optimizer)"
}