Pallet Configuration Calculator

It computes cases-per-layer both ways — length along the pallet's length (orientation 1) and length along the pallet's width (orientation 2) — by flooring pallet dimension divided by case dimension in each direction, then multiplying rows by columns for each. Whichever orientation yields more cases in a single layer wins and is reported as Best orientation; ties default to orientation 1.

The calculator computes two independent layer counts — layersByHeight (max stack height divided by case height) and layersByWeight (max pallet weight divided by the weight of one full layer) — and takes the smaller of the two as the actual number of layers. A dense case like canned goods often hits the weight ceiling well before the height ceiling, leaving unused vertical space even at maximum layers.

Volume utilization compares total case volume against the full stack envelope up to your entered maximum stack height, not the height the pallet actually reaches. If layering stops early because of the weight limit rather than the height limit, the pallet is using less of that theoretical envelope, so volume utilization drops even though every layer that was built is packed as densely as this model allows.

No — it uses a simple grid model, placing identical cases in straight rows and columns in one of two orientations. Real-world techniques like brick or pinwheel stacking, where rows are rotated relative to each other, can sometimes fit more cases per layer than a uniform grid, so this tool's case counts should be treated as a solid baseline rather than the absolute maximum achievable.