Standard pallet sizes and carton-fit examples

Choose the operational pallet, not the convenient preset

Common planning footprints include 1,200 × 800 mm Euro pallets, 1,200 × 1,000 mm industrial pallets, and approximately 48 × 40 inch GMA pallets. A preset saves typing, but the physical pallet, pool specification, customer requirement, and racking system control the approved dimensions.

Record pallet base height as well as footprint. A transport limit stated as total loaded height includes the pallet, caps, and other stabilisation materials.

Test both right-angle carton orientations

For a 1,200 × 1,000 mm pallet and a 400 × 300 mm carton, one straight-row orientation fits 3 × 3 cartons while the rotated orientation fits 4 × 2. The better simple pattern is nine cartons per layer, but a mixed pattern or packaging-design tool may find another arrangement.

Footprint utilisation is a useful signal, not a safety score. A high percentage can still leave an unstable edge, block labels, or conflict with automated handling.

• Use finished carton dimensions.
• Prohibit overhang unless explicitly approved.
• Trial the pattern at normal packing speed.

Connect the pattern to downstream limits

Multiply cartons per layer by complete layers, then cap the result by load weight, finished height, pallet rating, carton compression, and handling constraints. The smallest approved limit becomes the operating quantity.