Packaging & Logistics worked example

Cartons Per Pallet at 72% layer fill rate: a worked example

This worked example runs the cartons per pallet numbers for a tougher week than the baseline: 72% layer fill rate instead of the typical 100%. Estimate how many cartons fit on a pallet from cartons per layer, layers high, and how completely each layer and pattern fills.

The inputs for this scenario

  • Cartons per layer: 8 cartons / layer (held at the documented default)
  • Layers per pallet: 6 layers (held at the documented default)
  • Layer fill rate: 72 % (the input this scenario stresses; the baseline uses 100)
  • Stacking pattern efficiency: 96 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross cartons per pallet = cartons per layer × layers per pallet.
  • Net cartons per pallet works out to 33.18 cartons at these inputs, and this is the headline figure for the scenario.
  • Gross cartons per pallet works out to 48 cartons at these inputs.
  • Layer fill loss works out to 13.44 cartons at these inputs.
  • Pattern efficiency loss works out to 1.38 cartons at these inputs.

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 28% below the baseline at 33.18 cartons.
  • Use it when planning pallet configurations, quoting freight by the pallet, or sizing warehouse rack positions for a given SKU. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Net cartons per pallet: 33.18 cartons (headline result)
  • Gross cartons per pallet: 48 cartons
  • Layer fill loss: 13.44 cartons
  • Pattern efficiency loss: 1.38 cartons

Run it with your numbers

  • To rerun this with your own numbers, open the live Cartons Per Pallet calculator, set layer fill rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.