Build a pallet loading plan before the warehouse starts

Calculate the geometric ceiling

Start with the usable pallet footprint and test both 90-degree carton orientations. Multiply the best whole-carton count per layer by the number of full layers allowed by the load-height limit. This gives a geometric ceiling, not yet a safe capacity.

Include pallet base height when the transport limit is a total height. Do not count a partial layer unless the warehouse has a documented mixed-layer pattern.

• No overhang unless the operation explicitly allows it.
• Reserve height for caps, edge boards, or dunnage.
• Use finished carton dimensions.

Apply weight and strength limits

Divide the allowed load weight by gross carton weight and round down. Compare that number with the geometric ceiling. Then verify the pallet's rated capacity, racking condition, forklift handling, vehicle limits, and the bottom cartons' compression performance.

Interlocking patterns can improve stability but often reduce vertical compression strength. Column stacking can improve compression alignment but may require stretch wrap, corner boards, or other stabilisation. Treat the pattern as an operational standard, not an illustration.

Issue a one-page load specification

The approved specification should show pallet type, cartons per layer, layers, total cartons, finished height, load weight, orientation, wrap method, and a photo or simple pattern. Add a revision date so old instructions do not survive a packaging change.