Free tool
How many pallets, and what binds first
Freight is priced on pallets, so the pallet count is the number worth getting right. This tries both stack orientations, solves layers by height and by weight, and tells you which of the two is actually limiting you.
- Runs in your browser
- Footprint drawn to scale
- Both stack orientations tried
Pallet
48 × 40 in deck, 5.5 in tall. Stack height is measured from the floor, so the deck is subtracted.
Case
Cases per layer
6
Straight orientation
Layers high
5
Limited by height
Cases per pallet
30
180 units per pallet
Pallets needed
3
84 cases for 500 units
Trailers
1
At 26 floor spots per 53′ van
Gross weight
2,016
Pounds, cases only — pallets not included
Layer footprint
2 × 3 cases per layer
Deck coverage
79%
Case footprint
19.5 × 13 in
Binding constraint
height
Only 79% of the deck is covered. An overhang-free repack or a different case size would cut your pallet count, and freight is priced on pallets.
Worth knowing
Trailer fit assumes 26 floor spots in a 53′ dry van with pallets loaded straight and not double-stacked. Pinwheeling, turned pallets, or a stackable freight profile all change that number.
Gross weight counts cases only. Add roughly 35–40 lb per wooden pallet before comparing against a carrier weight limit.