What is a pallet stacking pattern?

A pallet stacking pattern defines how boxes or cartons are arranged on a pallet layer by layer. The most common patterns are aligned (all boxes in the same orientation, row by row), brick (alternating rows offset by half a box length for better stability), and pinwheel (groups of four boxes rotated 90° for interlocking stability). The right pattern depends on box size, pallet size, and whether load stability or maximum count is the priority.

Which pattern fits the most boxes per layer?

It depends on the ratio of box dimensions to pallet dimensions. The aligned pattern typically fits the most boxes when box dimensions divide evenly into pallet dimensions. The brick pattern sacrifices one or two boxes per row for significantly better load stability — less toppling during transport. The generator tests both orientations (box rotated 0° and 90°) and picks whichever gives the higher count.

What pallet sizes are supported?

The generator includes EUR/EPAL (1200 × 800 mm), EUR2 (1200 × 1000 mm), GMA/US Standard (48" × 40" = 1219 × 1016 mm), T-11 Japan (1100 × 1100 mm), and CHEP Australia (1165 × 1165 mm). You can also enter any custom pallet dimensions.

How is pallet utilization calculated?

Pallet utilization is the percentage of the pallet surface area covered by boxes in a single layer: (number of boxes per layer × box length × box width) ÷ (pallet length × pallet width) × 100. A utilization above 85% is considered good. Values below 70% suggest reconsidering box orientation or pallet size.

What is the maximum stack height?

Maximum stack height is the total height limit for a loaded pallet, including the pallet board itself (typically 144–160 mm for EUR pallets). Standard limits are 1800 mm for road transport (some carriers allow up to 2200 mm), 1600 mm for air freight (due to ULD constraints), and up to 2400 mm for warehouse storage. Always confirm with your carrier and warehouse before loading.

Can I use this for mixed SKU pallets?

This generator calculates patterns for a single box size. For mixed SKU pallets with different carton sizes, the pattern needs to be planned manually or with a full 3D load optimiser. As a rule of thumb, place the heaviest boxes on the bottom layers and the lightest on top, and try to keep each layer at a consistent height to maintain a flat stacking surface.

Free Pallet Pattern Generator

Enter your box and pallet dimensions to generate the optimal stacking pattern, boxes per layer, and total cartons per pallet.

Pallet Size

Box Length (mm)

Box Width (mm)

Box Height (mm)

Max Stack Height (mm)

Stacking Pattern

Boxes per layer

Layers

Total boxes

100%

Pallet utilization

1750 mm

Stack height

Top View — Layer Pattern

Side View

Pallet Pattern Generator — FAQ

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