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Pallet Pattern Optimisation Calculator

Work out pallet pattern optimisation instantly with clear inputs, formula shown and shareable results.

About Pallet Pattern Optimisation Calculator

Layer count is the best of the simple aligned patterns in each orientation. Utilisation is the case footprint area against the pallet area; good patterns exceed 90%. Poor utilisation means paying to ship air, and it compounds through every layer and every truck.

Formulas

Pallet layer count

Cases = max over orientations of floor(pallet L / case L) x floor(pallet W / case W)

Utilisation

Utilisation % = cases x case footprint x 100 / pallet footprint

Worked example

With the default values below, Pallet Pattern Optimisation Calculator returns Cases Per Layer of 9. Change any input above and every figure here is recalculated in your browser.

Inputs used

Pallet Lengthminimum 1 mm
1,200 mm
Pallet Widthminimum 1 mm
1,000 mm
Case Lengthminimum 1 mm
400 mm
Case Widthminimum 1 mm
300 mm

Results

Cases Per Layer
9
Best Pattern
Block (all aligned)
Pallet Area Utilisation
90.00%
Unused Pallet Area
0.12000

Step by step

  1. 1Values used
  2. 2Pallet layer count
  3. 3Utilisation
  4. 4Cases Per Layer= 9
  5. 5Best Pattern= Block (all aligned)
  6. 6Pallet Area Utilisation= 90.00
  7. 7Unused Pallet Area= 0.12000

Assumptions and limits

  • The result is derived only from the 4 inputs listed above. Anything not among them is not part of the calculation.
  • In particular, this calculator does not take inflation, tax, fees or charges or compounding frequency into account.
  • Figures are rounded for display to 5 decimal places, so totals built from several rounded parts can differ slightly from the unrounded arithmetic.

How these calculators are built and tested is described on the Methodology page. If a figure looks wrong, please report it.

Frequently Asked Questions

What about pinwheel and brick patterns?

They can beat aligned blocks when case dimensions do not divide the pallet neatly, and they interlock between layers for stability. Pattern software or physical trial is needed to confirm the count.

Should cases overhang the pallet?

Never intentionally. Overhang cuts compression strength by 20-40% because the case corners, which carry the load, are unsupported.

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