Unit loads: boxes on a pallet
A unit load is the box, the pallet and the pattern working together. The box size decides how many fit per layer, the pattern decides how strong the stack is, and the pallet footprint decides whether anything overhangs.
Boxes per layer
On a 48 × 40 in deck, a box that divides both sides evenly loads with no waste. Odd sizes leave gaps; turning some rows 90° (a two-zone pattern) often recovers one or two boxes per layer.
| Case outside, in | Per layer | Layers to 60 in | Per pallet | Deck covered |
|---|---|---|---|---|
| 12 × 10 × 8 | 16 | 6 | 96 | 100% |
| 16 × 12 × 10 | 9 | 5 | 45 | 90% |
| 13 × 11 × 9 | 12 | 6 | 72 | 89% |
| 18 × 12 × 12 | 8 | 4 | 32 | 90% |
| 20 × 16 × 12 | 6 | 4 | 24 | 100% |
Column or interlock
Column stacking lines corners up over corners and keeps the strongest parts of each box in line. Interlocking turns alternate layers to tie the load together, at a cost in compression strength. Stretch wrap and corner boards can give stability without interlocking.
Overhang
Even half an inch of overhang puts the box wall's strongest edge outside the deck. If the box does not fit, change the box, not the pallet. Pallet pricing and sourcing are covered on Packgent's sister site, palgent.com.
Use it
- Pallet pattern
- Stacking strength
- Unit load
- Overhang
- Bulk
- Right-sizing boxes to cut dimensional weight
- Reading a box maker's certificate
- Stacking strength and safety factors
Last reviewed 2026-10-27. Formulas and sources: method, sources.