CAP Ø 103 mm

Divider Thickness 3 mm
Cap Height 7 mm

Current Box Size:

L525mm W350mm H430mm [do we any play or should we keep it strictly below 430mm?]

Box Height Options:

3 layers/box ► (Ø103+3)x3= 318mm
4 layers/box ► (Ø103+3)x4= 424mm

Presuming a 4 mm box thickness maximum external heights are:

3 layers/box ► 326 mm
4 layers/box ► 432 mm [can we go for this one?]

Box Width Options:

I would leave some play between stacks on the same layer, let’s say 2mm that means
Ø103+2=105mm, so our box internal-width should be multiple of 105, this is:

Box Width Box Width How they fit in the pallet

Internal External 1200 1000 800

2 stck/lyr 210 218 (x5) 1090 (x4) 872 (x3) 654

3 stck/lyr 315 323 (x4) 1292 (x3) 969 (x2) 646

4 stck/lyr 420 428 (x4) 1284 (x2) 856 -

5 stck/lyr 525 533 - (x2) 1066 -

6 stck/lyr 630 638 (x2) 1276 - -

According to this, if we use a 1200x1000 pallet, our box External Dimension should be as follows:
W323mm x L600mm x H432mm

As we have clearance enough on the pallet I would leave extra play and make Box Width 328mm.

So the final size of the box is:

External: W328 x L600 x H432
Internal: W320 x L592 x H424
 Quantities for this are:
12 stacks per box
82 caps per stack
984 caps per box
18 box per pallet [6 per layer, 3 layers high]
17,712 caps per pallet