Packaging & Logistics worked example

Truckload Pallet Capacity at 110% usable floor positions: a worked example

What does the result look like when usable floor positions reaches 110%? The full calculation is worked below with real intermediate numbers. Use it to plan truckload and container builds, compare single versus double stacking, and avoid overestimating positions on a 53 foot trailer.

The inputs for this scenario

  • Floor pallet positions: 26 positions (unchanged)
  • Stack height: 2 pallets high (unchanged)
  • Usable floor positions: 110 % (raised for this scenario; the documented default is 100)
  • Stackable load share: 90 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross truckload pallet capacity = floor pallet positions × stack height) to the inputs above produces each figure below.
  • At this operating point the engine returns 51.48 pallets for net pallets per load, the number this scenario is built around.
  • At this operating point the engine returns 52 pallets for gross pallet positions.
  • At this operating point the engine returns -5.2 pallets for unusable floor loss.
  • At this operating point the engine returns 5.72 pallets for non-stackable loss.

How this compares with the baseline

  • Against the tool's baseline example, where usable floor positions sits at 100% and the headline result is 46.8 pallets, this scenario comes in 10% above the baseline at 51.48 pallets.
  • A figure at this level is achievable when usable floor positions is genuinely sustained, not just peaked for a shift. It assumes uniform pallets; mixed heights, weights, and non-stackable SKUs in the same load can push the real number below the calculated net.

Results at a glance

  • Net pallets per load: 51.48 pallets (headline result)
  • Gross pallet positions: 52 pallets
  • Unusable floor loss: -5.2 pallets
  • Non-stackable loss: 5.72 pallets

Run it with your numbers

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

Last reviewed 2026-05-12.