Work out pallet pattern optimisation instantly with clear inputs, formula shown and shareable results.
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.
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
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.
Never intentionally. Overhang cuts compression strength by 20-40% because the case corners, which carry the load, are unsupported.