How Many Boxes Fit on a Pallet?
The number of boxes that fit on a pallet depends on two things: how many boxes fit in one layer, and how many layers you can stack within the height and weight limits. Multiply those together and you have your answer. Below is the formula, a worked example, and a reference table for the most common box sizes on a standard 48×40 GMA pallet.
The formula for boxes per pallet
Everything else is just working out those two numbers. You solve them by comparing the box footprint to the pallet deck, and the box height to your usable stacking height.
Step 1 - Boxes per layer (the Ti)
A standard GMA pallet measures 48×40 inches, giving a deck area of 1,920 square inches. To find how many boxes fit in one layer, divide the pallet footprint by the box footprint - but remember boxes must sit flat and can be rotated, so the real answer often comes from fitting them in a pattern rather than raw area division.
Raw area division gives an upper bound. In practice you lose some space to the box pattern, so treat the area result as a starting point and then confirm with an actual layout.
Step 2 - Number of layers (the Hi)
Usable stack height is your maximum load height minus the pallet's own height. A GMA pallet is about 5-6 inches tall. If your carrier or program caps total height at 72 inches, and the pallet is 6 inches, you have roughly 66 inches to stack - but many shippers plan to a conservative 60 inches of usable box height to leave room for stretch wrap, a slip sheet, and a safety margin. Round down; you cannot stack a partial layer.
Worked example
Let's use a common shipping box: 16 × 12 × 12 inches, weighing 20 lb each, on a 48×40 pallet with 60″ of usable height.
- Boxes per layer: Lay boxes with the 16″ side along the 48″ pallet length and the 12″ side along the 40″ width. That is 3 across (48 ÷ 16) × 3 deep (40 ÷ 13.3, but the 12″ dimension fits 3 with room to spare) = 8 boxes per layer in a clean interlocked pattern. Raw area division (1,920 ÷ 192) suggests 10, so 8 is the realistic packed count.
- Layers: 60″ usable ÷ 12″ box height = 5 layers.
- Boxes per pallet (height): 8 × 5 = 40 boxes.
- Weight check: 40 boxes × 20 lb = 800 lb + ~40 lb pallet = 840 lb. That is under 1,500 lb, so height is the limiting factor. Final answer: 40 boxes.
If those same boxes weighed 45 lb each, 40 boxes would be 1,800 lb - over the limit. You would be capped at about 32 boxes (4 layers, ~1,480 lb) instead, and weight becomes the limiting factor.
Reference table: boxes per pallet by box size
Approximate counts on a 48×40 GMA pallet with 60″ usable stacking height, assuming a practical packed layout (not raw area division) and column-stacked layers. Your real count varies with stacking pattern, overhang rules, and weight caps.
| Box size (L×W×H, in) | Box footprint (sq in) | Boxes per layer (Ti) | Layers @ 60″ (Hi) | Approx. boxes per pallet |
|---|---|---|---|---|
| 12 × 12 × 12 | 144 | 10 | 5 | 50 |
| 16 × 12 × 12 | 192 | 8 | 5 | 40 |
| 18 × 18 × 16 | 324 | 5 | 3 | 15 |
| 20 × 16 × 14 | 320 | 6 | 4 | 24 |
| 24 × 20 × 20 | 480 | 4 | 3 | 12 |
Counts assume boxes stay within the pallet footprint with minimal overhang. Always verify weight stays under your program's limit - a fully packed pallet of heavy boxes can hit the weight cap before it hits the height cap.
What are Ti and Hi?
Ti and Hi are the standard shipping terms behind the formula:
- Ti (tie) = the number of boxes (cartons) in a single layer on the pallet - your boxes per layer.
- Hi (high) = the number of layers stacked on top of each other - your number of layers.
So Ti × Hi = cartons per pallet. A pallet spec written as "Ti 8, Hi 5" means 8 boxes per layer, 5 layers, for 40 boxes total. It is the same formula, just in industry shorthand. For a deeper walkthrough, see our Ti Hi calculator guide.
Tips to fit more boxes per pallet
- Orient the box to reduce wasted deck space. Rotating boxes 90° or mixing orientations (a "pinwheel" pattern) often adds one more box per layer.
- Match box height to a clean division of your usable height. A 10″ box gives 6 layers in 60″; an 11″ box wastes 5″ and only gives 5 layers.
- Design the box to the pallet. If you control the carton, size it so a whole number of boxes tiles the 48×40 deck with little waste.
- Watch overhang. Boxes hanging over the pallet edge lose compression strength and may be rejected. Keep the load inside the footprint.
Stop guessing - calculate it in seconds
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Try the Free Pallet Calculator Amazon FBA Pallet CalculatorFrequently asked questions
How many boxes fit on a standard pallet?
It depends on box size, but a typical 48×40 GMA pallet holds roughly 40-50 medium shipping boxes (around 16×12×12 in) stacked to 60″, or as few as 12-15 large boxes. Use the formula boxes per layer × number of layers, and always confirm the load stays under the weight limit.
What is the standard pallet size in the US?
The most common is the GMA (Grocery Manufacturers Association) pallet at 48×40 inches, about 5-6 inches tall. It is the default for Amazon FBA, Walmart, and most retail supply chains in North America.
How tall can I stack boxes on a pallet?
Programs commonly cap total load height (pallet included) at 72 inches. After subtracting the pallet, plan for about 60 inches of usable box height to leave room for stretch wrap and a safety margin. Always round the layer count down.
Does box weight change how many fit?
Yes. Even if height allows more layers, you must stay under the weight cap - commonly 1,500 lb including the pallet for Amazon FBA. Heavy boxes hit the weight limit before the height limit, so weight becomes the deciding factor.
What is the difference between Ti and Hi?
Ti is the number of boxes in one layer (boxes per layer); Hi is the number of layers stacked. Ti × Hi equals total boxes per pallet.