Automatic Layout Optimisation
Every calculation tests both 0° and 90° carton positions to maximise pallet utilisation while maintaining a level, practical load.
Air Freight Tools
Pallet Calculator
Calculate how many boxes or cartons fit on UK, Euro, half or custom pallets. Optimise the pallet layout and review loaded height, gross weight, volumetric weight and air freight chargeable weight before booking your shipment.
Start CalculationCarton Stacking and Pallet Planning
Pallet Load Calculator for Air Freight Shipments
Calculate how many boxes or cartons fit on a pallet, together with loaded height, gross weight, volumetric weight and air freight chargeable weight. Enter one uniform carton size, choose the pallet and confirm whether cartons may be tipped onto another face.
Why This Calculator Is Different
Practical Pallet Planning for Air Freight
Mixed-Orientation Support
Where tipping is permitted, the optimiser also tests alternative carton faces and mixed orientations to identify the best usable layout.
Air Freight Chargeable Weight
Gross weight includes the cartons and empty pallet. The result compares gross and volumetric weight to identify the airline chargeable weight.
Interactive Calculator
Build Your Pallet
No registration required. Calculations are completed instantly in your browser.
- 1Carton
- 2Pallet
- 3Packing rules
- 4Result
Air Freight Planning Guidance
Understanding Pallet Chargeable Weight
Air freight rates are normally calculated using the shipment’s chargeable weight. This is the greater of the actual gross weight and the calculated volumetric weight. For a palletised shipment, gross weight includes the packed cartons and the tare weight of the pallet itself.
Volumetric weight reflects the space occupied by the loaded pallet. The calculator uses the pallet footprint, overall loaded height and selected airline divisor to produce an indicative volumetric weight. A divisor of 6000 cm³/kg is commonly used, although some airlines, services and tariffs use 5000 cm³/kg.
Loaded height also affects handling. Pallets up to 160 cm overall height can generally pass through primary airline cargo screening equipment. Taller freight may require secondary screening, additional handling or repacking, depending on the airline, airport and cargo facility.
A practical air freight pallet should remain within the pallet footprint wherever possible, use stable carton orientations and present a level top. The result is an operational planning guide; final acceptance remains subject to airline, terminal, security, weight-distribution and packaging requirements.
Frequently Asked Questions
Pallet Calculator FAQs
How many boxes fit on a UK pallet?
The number of boxes or cartons that fit depends on the external dimensions, permitted orientation, maximum loaded height and any pallet weight limit. A standard UK pallet is 120 × 100 cm, and this calculator tests practical mixed-orientation layouts automatically.
What is the standard size of a Euro pallet?
A standard Euro pallet measures 120 × 80 cm. The calculator applies a 20 kg indicative tare weight and allows you to calculate carton capacity, layers, loaded height and chargeable weight.
Does gross weight include the pallet?
Yes. The calculated gross weight includes the total weight of the cartons plus the empty pallet weight. UK, Euro and half-pallet tare weights are applied automatically, while custom pallets use the weight you enter.
How is air freight chargeable weight calculated?
Chargeable weight is the greater of gross weight and volumetric weight. The calculator compares both values and shows which one forms the chargeable basis.
Why does the calculator rotate cartons?
Turning a carton through 90° on the same base can improve use of the pallet footprint. The optimiser tests both positions automatically and may combine orientations within the same layer.
What does permitting cartons to be tipped mean?
It allows another carton face to become the base. Select this only where the product, packaging and handling instructions permit the carton to be placed safely on its side.
Can cartons overhang the pallet?
The normal setting for air freight is no overhang. A limited allowance can be entered where appropriate, but overhanging cartons are more exposed to damage and may be refused by an airline or cargo terminal.
Why is 160 cm used as the screening threshold?
An overall height of 160 cm is used as an indicative primary airline screening threshold. Taller pallets may require secondary screening or alternative handling, subject to the departure airport and screening facility.
Can I calculate a custom pallet?
Yes. Choose Custom pallet and enter the pallet length, width, empty height and tare weight. All custom fields begin blank so the result is based only on the information supplied.
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