IDCalcs

Pallet utilization for industrial designers.

Estimate carton count, display height, weight, and club-store compliance while previewing the stack as a practical 3D display layout.

Cartons / Layer0
Total Cartons0
Total Height0"
Total Weight0 lb
Shoppable Cartons0
Filler Cartons0

3D Display Preview

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Top View

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Filler cartons are positions no shopper can reach from an open side. Spec them as dead corrugate cube, riser structure, or backstock instead of sellable product, and the display costs less to fill while looking just as full.

Compliance Check

General Use

Costco

48 x 40 block pallets only (CHEP, PECO, or iGPS), no overhang, product shoppable from three sides with a 48 in main facing.

  • Recommended product footprint: 47.5 x 39.5 in (min 44 x 37)
  • Max 58 in total height including the 5.5 in pallet
  • 52 in or less to double-stack in transit
  • Max total load: 2,500 lb

Sam's Club

48 x 40 full 9-block pallets with true four-way entry. Quarter and half pallet programs also run under the same block-pallet rules.

  • Up to 60 in display height in club, 52 in for transit double-stack
  • Lower planning cap than Costco: 2,100 lb
  • Pallet skirts not allowed
  • 40 in side is the primary facing

BJ's Wholesale

BJ's guidance is thinner in public sources, so this mode uses conservative club-store defaults.

  • 48 x 40 four-way pallet baseline
  • 40 in main-facing assumption
  • Conservative 2,100 lb planning cap
  • Confirm tray and buyer packet requirements before release
Method: The calculator tests both carton orientations and uses the better count: max(floor(L / cartonL) × floor(W / cartonW), floor(L / cartonW) × floor(W / cartonL)). When a skirt is enabled, usable footprint becomes (palletL - 2t) × (palletW - 2t). The CHEP 48 x 40 block pallet itself is 5.5 in tall and rated for 2,800 lb uniformly distributed, so the retailer load caps below always govern first.
Constraints reflect publicly available club store vendor and structural packaging guidance, checked against retailer-published specs during the rebuild. Treat this as a design estimator, not a substitute for a current buyer/vendor packet.