Mixed carton pallet height: a worked order example

Total carton volume divided by pallet area does not tell you the actual loaded height. Box dimensions, allowed rotation, payload and height limits determine which arrangements fit. Start with the whole order, then check what remains unplaced.

The order and its limits

Use a 120 × 80 cm pallet with a 15 cm base, a 70 cm total height limit and a 750 kg cargo limit. Both carton types stay upright. No top-load strength data is supplied, so this example does not establish carton strength.

One pallet: 65 cm is only part of the order

With a one-pallet limit, the order-v1 engine places 4 large and 8 small cartons. Cargo height is 50 cm; adding the 15 cm base gives 65 cm. Eight large cartons remain. Do not use that height as evidence that the entire shipment fits.

Allow three pallets: all 20 cartons fit

The same order with a three-pallet limit has zero cartons remaining. These are feasible geometric placements found by the algorithm, not proof that three is the mathematical minimum. The cargo weighs 128 kg in total, excluding empty pallets, wrapping and straps.

Try it with your shipment

1. Download the example order JSON
2. Open the pallet height calculator and import the file under “Saved orders”. Change the pallet limit between 1 and 3.
3. Inspect each pallet from above and from the side, then play the carton sequence. Check remaining quantities before printing.
4. Replace the example dimensions and constraints with your own. After loading, record the measured height and compare it with the estimate.

Before sending a plan to the warehouse, confirm carton strength, permitted orientation and securing requirements with the people handling the load. A 3D placement diagram alone does not establish transport stability.