How to use this calculator
- Enter or choose storage type.
- Enter or choose target utilisation.
- Enter or choose pallets stored now.
- The pallet positions updates as you type. Use Copy result or Share to keep it.
Method
Racking: Positions = Bays × Levels × Pallets per level. Floor: Positions = ⌊Area × (1 − Aisle%) ÷ Pallet footprint⌋ × Stack height. Utilisation = Stored ÷ Positions
- Levels
- beam levels plus the floor position, if used
- Aisle%
- floor share taken by aisles, clearances and staging
- Stack height
- pallets stacked on top of each other
Worked example
- Positions = 40 × 4 × 2 = 320.
- Working capacity at 85% = 320 × 0.85 = 272.
- Utilisation = 250 ÷ 320 = 78.13%; free = 70.
The racking has 320 pallet positions; at an 85% working target that is 272, and 250 stored means 78% full.
What the result means
Running close to 100% slows receiving and put-away because there is nowhere to move stock. If you are regularly above your target, plan extra space or reduce slow-moving stock before peaks.
Assumptions and limits
- Every position takes one standard pallet.
- Floor stacking uses whole pallet footprints only; partial footprints are dropped.
- Racking load ratings, floor loading, fire-code clearances and stack stability are not checked. Follow the rack supplier’s and local safety requirements.
Questions
What aisle allowance should I use for floor stacking?
It depends on the forklift and layout. Measure a section of your own floor and divide the pallet area by the total area to get your figure.
Does this tell me how many cartons fit on a pallet?
No. It counts pallet positions in the building, not cartons per pallet.
Please note: Quantities are estimates. Confirm requirements with your engineer or supplier before ordering materials.