How to Optimise Box Design for Pallet and Freight Efficiency
Optimise your box dimensions for pallets and freight to reduce shipping waste.
Pallet optimisation
Quick answer
Design box dimensions so they tessellate perfectly on a 1200x1000mm pallet with zero overhang. Common efficient footprints include 600x400mm (8 per layer), 400x300mm (10 per layer), and 300x200mm (20 per layer). Box height should allow maximum layers within vehicle height limits. Efficient pallet utilisation reduces per-box freight cost by maximising boxes per pallet. Even 5% better utilisation compounds into significant savings at scale.
Efficient box dimensions
A standard efficient footprint.
Good for medium-sized products.
Worth calculating for high-volume products.
Logistics: warehouse logistics or shipping costs.
Efficiency tips
Pallet efficiency0 / 3 checked
Pallet-efficient double wall boxes
Optimised dimensions from ProcuraPack.
Browse double wall boxesFrequently asked questions
Standard UK: 1200x1000mm.
600x400mm (8/layer), 400x300mm (10/layer), 300x200mm (20/layer).
Yes, poor pallet utilisation wastes freight space and money.
Yes, overhang risks damage and wastes pallet space.
For high-volume products, optimised dimensions save significantly.
Part of our guide
Product Guide: Double Wall Cardboard Boxes
Expert guides on double wall cardboard boxes for heavy-duty shipping and industrial packaging.
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