Free Pallet Calculator

Plan mixed pallets in seconds. Enter as many SKUs as you need, each with its own carton size, weight and count, and the calculator works out how many pallets you need, how to build each one layer by layer, and how tall and heavy each pallet will be. Then print a pallet build sheet for your warehouse team.

How to use the pallet calculator

1. Add your cartons. Enter each SKU with its carton length, width, height (inches), weight per carton (lb) and how many cartons you have. Or paste them straight from Excel or Google Sheets.
2. Set your pallet rules. Pick a pallet size and set the max height and max weight your carrier or customer allows.
3. Review your pallets. See the total pallets, cartons, weight and cube, every pallet in 3D, and a top view of each layer.
4. Print the build sheet. Download a PDF build sheet with every pallet and layer laid out for the warehouse floor.

Built for mixed SKU pallets

Most pallet calculators only handle one carton size at a time. Real shipments usually mix SKUs. This calculator lets you plan them together:

• Any number of SKUs, each with its own dimensions, weight and count
• Full single SKU layers first, then mixed layers for the leftovers, to keep the pallet count down
• Height and weight limits that are never exceeded
• Option to let cartons lie on their side, and to even out pallet heights
• Color coded 3D pallets and layer by layer top views
• LTL freight class for every pallet
• A printable pallet build sheet for your warehouse team

Freight class calculator

The calculator also gives the LTL freight class of every pallet it builds. Freight class is based on density: the pallet’s weight divided by its outside size in cubic feet, with the pallet included. Since July 2025 the NMFC uses 13 density classes, from class 50 for the densest freight to class 400 for the lightest.

Density (lb per cubic foot)	Freight class
Less than 1	400
1 to under 2	300
2 to under 4	250
4 to under 6	175
6 to under 8	125
8 to under 10	100
10 to under 12	92.5
12 to under 15	85
15 to under 22.5	70
22.5 to under 30	65
30 to under 35	60
35 to under 50	55
50 or more	50

To find a class by hand, multiply length x width x height in inches, divide by 1,728 to get cubic feet, then divide the weight in pounds by the cubic feet. A 48 x 40 x 60 inch pallet weighing 1,000 lb is 66.7 cubic feet, or 15 lb per cubic foot, which is class 70. Some products have their own NMFC class, and your carrier has the final say.

Standard pallet sizes

Pallet size (inches)	Common uses
48 x 40	GMA standard: grocery, retail and most US shipping
48 x 48	Drums and totes
42 x 42	Telecom and paint
48 x 42	Chemical and beverage
40 x 40	Dairy
48 x 45	Automotive
36 x 36	Beverage

Tips for building better pallets

• Put the heaviest, strongest cartons on the bottom layers.
• Keep cartons inside the edge of the pallet. Overhang crushes corners and can be refused at the dock.
• Build full layers of one SKU where you can. They stack flat and are easier to count.
• Check your customer’s routing guide for pallet height, weight and label rules before you build.
• Stretch wrap from the pallet up and label two sides.

Pallet calculator FAQ

How many boxes fit on a pallet?

It depends on the carton size, the pallet size and your height limit. For example, an 18 x 12 x 10 inch carton fits 8 per layer on a 48 x 40 pallet. With a 72 inch height limit and a 5 inch pallet, that’s 6 layers, or 48 cartons per pallet. Enter your own carton dims above and the calculator works it out for you.

Can I put more than one SKU on a pallet?

Yes. Add as many SKUs as you need, each with its own carton size, weight and count. The calculator builds full single SKU layers first, then packs the leftovers into mixed layers so you use as few pallets as possible.

What is the standard pallet size in the US?

The most common pallet in the US is the 48 x 40 inch GMA pallet. The calculator also has 48 x 48, 42 x 42, 48 x 42, 40 x 40, 48 x 45 and 36 x 36 sizes, plus a custom size.

How tall can a pallet be?

Many carriers and warehouses cap pallets around 72 inches including the pallet, but retailers and carriers set their own limits. Check your routing guide or carrier rules and set the max height to match.

How much weight can a pallet hold?

A standard wood pallet is commonly loaded up to about 2,500 lb for shipping, but your carrier or customer may set a lower limit. Set the max weight in the calculator and it will never go over it.

What is a pallet build sheet?

A build sheet is a printable plan for the warehouse floor. It shows every pallet layer by layer, which cartons go where, and the height and weight of each pallet, so the team builds it right the first time.

Is the pallet calculator free?

Yes. It’s free with no sign up. Your cartons are saved in your own browser so they’re there next time.

Can IronLink build and ship my pallets?

Yes. IronLink Logistics runs warehouses in Ontario, CA, Riverside, CA and Swedesboro, NJ. We receive containers, store inventory and build retail compliant pallets for Walmart, Target, Costco, Home Depot and more.

How do I find my freight class?

Divide the weight of the pallet by its size in cubic feet (length x width x height in inches, divided by 1,728) to get its density, then look up the class on the NMFC density scale. This calculator does it for every pallet automatically.

What freight class is a pallet?

A pallet has no fixed class. It depends on its density. For example, a 48 x 40 x 60 inch pallet weighing 1,000 lb is about 15 lb per cubic foot, which is class 70 on the NMFC density scale in effect since July 2025.

Want us to build and ship your pallets?

IronLink Logistics is a bicoastal 3PL. We receive containers from the Ports of Los Angeles, Long Beach, New York/New Jersey and Philadelphia, store your inventory, and build and ship pallets to Walmart, Target, Costco, Home Depot and other retailers, built to each routing guide. Our warehouses are in Ontario, CA, Riverside, CA and Swedesboro, NJ.