Nested Trays per Carton Stack Calculator
Find the maximum number of nested molded fiber trays in one vertical carton stack using internal carton height, packing clearance and measured nesting pitch.
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Replace the example values with figures from your supplier sheet or measurements. Choose the unit beside each value. Results update as you type; fix any highlighted field before using the result.
GSM means grams per square metre. Net weight excludes the core and other packaging. MOQ means the minimum order quantity. An optional field can stay blank unless the result you need depends on it.
Prices keep the selected currency; changing its label does not convert an exchange rate. Save or export the result after checking your inputs.
Maximum trays in one carton stack
Assumes one vertical stack per carton. Tray footprint must fit the internal carton length and width separately.
Use the measured additional pitch of each nested tray. Deformation and compression are not modeled.
Trays/stack = floor((internal height − clearance − first tray height) ÷ nesting pitch) + 1, or zero when first tray does not fit
Usable height 840 mm; 99 trays occupy 834 mmSaved calculations stay in this browser. No account or cloud backup is created.
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Calculated from your inputs. Confirm specifications with your supplier.
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All other entered inputs stay fixed. Ranges are your scenarios, not statistical confidence or supplier performance predictions. This uses the same validated calculator engine.
The formula, made clear.
The first tray occupies its full height, while each additional nested tray adds only the measured incremental pitch. Subtract the total top-and-bottom packing clearance from internal carton height before counting trays. This calculation assumes one vertical stack in each carton and does not place several stacks across the carton footprint. Check tray length and width against the box separately. Use measurements taken in the intended packing condition because imperfect nesting, deformation and manufacturing tolerances can change the practical count.
How to use this calculator
- 01
Enter internal carton height and total vertical clearance for wrapping and packing.
- 02
Enter full height of the first tray and the additional height added by each nested tray.
- 03
Enter the order tray quantity.
- 04
Review maximum trays in one stack, occupied height and cartons required with one stack each.
A calculation you can check
For an 850 mm internal carton, 10 mm clearance, a 50 mm first tray and 8 mm nesting pitch, usable height is 840 mm. floor((840 − 50) ÷ 8) + 1 = 99 trays occupy 834 mm, leaving 6 mm below the reserved clearance. Packing 10,000 trays needs 102 cartons with one stack each.
- Internal carton height
- 850 mm
- Total vertical packing clearance
- 10 mm
- First tray height
- 50 mm
- Additional nesting pitch
- 8 mm
- Trays to pack
- 10000 units
Usable height 840 mm; 99 trays occupy 834 mmFrequently asked questions
Is nesting pitch the same as tray height?
No. Nesting pitch is the extra stack height added by each additional tray. Measure it from a representative stack rather than using the full tray height.
Does the result include several stacks in one carton?
No. It counts one vertical stack. Any arrangement of several stacks requires a separate footprint and packing-fit check.
Check the displayed formula and units against your quotation. Use measured GSM, net weight and actual layout dimensions where available. Default densities are planning assumptions, not certified material properties. Calculated cost does not certify strength, compatibility or safe loading.
Method, units and material assumptions ↗