The basic calculation
A simple planning estimate starts with how many cartons fit on one layer and how many layers can be stacked. Multiply those figures to estimate cartons per pallet.
Cartons per pallet = cartons per layer × layers per palletWorked example
If 8 cartons fit on each layer and you can stack 5 layers, one pallet holds 40 cartons. A 95-carton shipment would require 3 pallets, with 15 cartons on the partial pallet.
Estimate cartons per layer from dimensions
If you do not already know the cartons-per-layer count, compare the pallet deck dimensions with the carton footprint. A quick rectangular estimate is:
Cartons per layer ≈ floor(pallet length ÷ carton length) × floor(pallet width ÷ carton width)Then rotate the carton 90 degrees and calculate the second orientation. Use the larger simple result as a starting estimate. Mixed or interlocking patterns can sometimes fit differently, so a physical layout or warehouse standard should override the simple formula.
48 × 40 pallet example
On a 48 × 40 inch pallet, a 12 × 10 inch carton fits 4 cartons along the 48-inch side and 4 along the 40-inch side, or 16 cartons in a simple layer. At 5 layers, that is an estimated 80 cartons per pallet before checking height, weight, stacking strength and handling limits.
What to check before using the result
Real pallet capacity also depends on pallet dimensions, carton orientation, overhang, crush strength, stacking rules, height limits and weight limits.
Use the result as part of shipment preparation, then keep the final dimensions, weights and package counts consistent with the packing list, carrier instructions and other paperwork.