Packaging & Logistics worked example

Cartons Per Pallet at 110% layer fill rate: a worked example

Push layer fill rate up to 110% and the picture changes. This example computes every intermediate figure at that operating point. Use it to plan pallet patterns, set ti-hi (cartons per layer by layers high), and confirm cartons per pallet before you build loads.

The inputs for this scenario

  • Cartons per layer: 8 cartons / layer (unchanged)
  • Layers per pallet: 6 layers (unchanged)
  • Layer fill rate: 110 % (raised for this scenario; the documented default is 100)
  • Stacking pattern efficiency: 96 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross cartons per pallet = cartons per layer × layers per pallet) to the inputs above produces each figure below.
  • At this operating point the engine returns 50.69 cartons for net cartons per pallet, the number this scenario is built around.
  • At this operating point the engine returns 48 cartons for gross cartons per pallet.
  • At this operating point the engine returns -4.8 cartons for layer fill loss.
  • At this operating point the engine returns 2.11 cartons for pattern efficiency loss.

How this compares with the baseline

  • Against the tool's baseline example, where layer fill rate sits at 100% and the headline result is 46.08 cartons, this scenario comes in 10% above the baseline at 50.69 cartons.
  • It multiplies cartons per layer by layers per pallet for a gross count, then discounts by layer fill rate and stacking-pattern efficiency to give a realistic net cartons per pallet. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Net cartons per pallet: 50.69 cartons (headline result)
  • Gross cartons per pallet: 48 cartons
  • Layer fill loss: -4.8 cartons
  • Pattern efficiency loss: 2.11 cartons

Run it with your numbers

  • Every input above is editable in the live Cartons Per Pallet calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.