A pallet with one carton size is relatively straightforward: estimate a strong layer pattern, calculate the number of complete layers and check weight. Mixed-SKU loads are harder because different footprints and heights compete for the same space.
Why a simple area ratio is not enough
Dividing pallet area by total carton area can overstate capacity because rectangular pieces do not always tessellate cleanly. A narrow unused strip can remain even when the theoretical area looks sufficient.
Height creates another packing layer
When cartons have different heights, the height assigned to a layer is usually determined by the tallest carton in that layer. Shorter cartons can leave vertical space that a simple volume ratio treats as usable even though it may not be operationally accessible.
Weight is a separate constraint
A geometric arrangement can still exceed pallet, rack or handling limits. Every mixed-load plan should track both geometry and gross weight.
The Mixed-SKU Pallet Planner uses a transparent greedy shelf-and-layer heuristic. It is designed to create a repeatable planning scenario, not to claim a mathematically optimal 3D solution.
When a heuristic is useful
Heuristics are valuable for comparing packaging alternatives, estimating pallet count and identifying obviously poor combinations. They are especially useful before a warehouse team spends time on a detailed physical load plan.
What still needs human validation
- Carton compression and stack compatibility.
- Heavy items below lighter items.
- Center of gravity and pallet stability.
- Label and pick accessibility.
- Overhang and customer specifications.
- Stretch wrap, corner boards and other securing material.
The best workflow uses software to reduce the search space and people to validate the constraints the software cannot fully see.