This article contains everything you need to know about Shipping Pallets.
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A shipping pallet serves as a base platform designed to support items, products, equipment, and materials for streamlined handling during transportation and storage. Introduced alongside the invention of forklifts in the early 20th century, pallets replaced traditional storage methods like kegs, boxes, and barrels. This innovation significantly transformed material storage, organization, and protection, becoming an essential component of warehousing. Today, nearly two billion pallets are in use worldwide.
The standard shipping pallet for North America and the United States is 48 x 40 x 6 and weighs between 30 lbs to 40 lbs. Although pallets come in a wide variety of sizes and shapes, the standard pallet is the most widely used due to its ability to easily fit onto warehouse racking. Pallets are made of various materials including wood, plastic, metal, paper, and recycled aluminum and paper. Of the various structural materials, wood is used the most.
Shipping pallets are specifically designed to be efficiently maneuvered using forklifts or pallet jacks for purposes like stacking, transportation, and storage. Different industries have created specialized pallet designs to enhance the protection of their products and simplify transport. Depending on the nature of the goods being shipped, extra security is often added by wrapping the materials in plastic film or securing them with straps.
Plastic pallets offer several benefits, including enhanced durability, strength, and cost-effectiveness, while also being resistant to microbes and chemicals. As a result, they are increasingly becoming the preferred material for pallets.
Given the critical role of shipping pallets in logistics and supply chains, various organizations set standards for pallet dimensions and sanitation. These regulations are designed to minimize delays and challenges during transport, while ensuring the health and safety of workers, end-users, and the biodiversity of the destination region.
Various materials can be utilized in the construction of shipping pallets, each offering unique advantages depending on the application:
Wooden pallets dominate the shipping industry due to their widespread use. They are ideal for transporting furniture, sealed goods, and non-biodegradable items. Known for their durability, these pallets can support heavy loads, are cost-effective, and easy to repair. Typically constructed from oak or pine, wooden pallets provide a high-friction surface, making them easy to grip during lifting operations.
Their substantial weight makes them expensive and challenging to transport. Wooden pallets are also prone to insect infestations, such as termites, due to their porous surfaces. Being organic, they are vulnerable to moisture, corrosion, chemicals, and microbial contamination. As a result, wooden pallets require frequent sanitization and are often coated with varnish to enhance resistance and extend their lifespan. There are engineered wooden pallet variations designed to mitigate these drawbacks:
Plywood pallets are notably lighter than traditional wooden pallets and are ideal for transporting light to medium weight goods. Pressure-treated plywood enhances resistance to pests and microbial growth. These pallets are durable, offer consistent strength, and maintain dimensional stability.
Engineered molded wood pallets are constructed from wood fibers, shavings, or recycled wood combined with resin and formed under high heat and pressure. These pallets are lighter than traditional wood pallets but match them in strength, durability, and rigidity. They are available in standard pallet sizes and are produced using molds to compress and heat the raw wood material and resin. Presswood pallets are incredibly strong and are more cost-effective than plastic pallets.
To meet IPPC ISPM-15 regulations, the wood fibers used in engineered molded wood pallets undergo intense heat treatment to eliminate pests and microorganisms. This process is crucial for preventing the spread of diseases in international shipments. These pallets bear a certification stamp that confirms compliance with IPPC ISPM-15 standards.
The IPPC ISPM-15 Certification Stamp includes the following elements:
Similar to traditional wooden pallets, molded wood pallets are prone to absorbing moisture when stored outdoors. To maximize their durability and lifespan, it is recommended to store them indoors.
Presswood pallets are made from wood fibers, shavings, or occasionally recycled wood, which are bonded and compressed to create a wooden block. While they are lightweight and customizable, they still share the common vulnerability of conventional wooden pallets to moisture damage.
Plastic pallets are crafted from polymeric plastic materials, produced through various molding techniques such as rotational molding, thermoforming, blow molding, or injection molding. These pallets are known for their durability, extended service life (which can exceed a hundred trips), and lighter weight compared to wooden and metal pallets. They are resistant to corrosion, odors, microbial, and chemical contamination. Plastic pallets do not absorb moisture and are easy to clean, making them ideal for use in the food, beverage, and pharmaceutical industries. Additionally, plastic pallets can be made from recycled plastics, although those made from 100% virgin plastics generally offer superior performance. However, repairing these pallets can be costly due to their seamless joints.
The commonly used polymeric plastic materials include:
PET plastics are known for being lightweight, cost-efficient, and highly recyclable. They have a surface that resists moisture, liquids, and gases. Belonging to the polyester family, PET is ideal for pallet manufacturing due to its rigidity and light weight.
HDPE plastics are noted for their high strength-to-density ratio and ability to retain strength at high temperatures. They are impact-resistant, making them effective in absorbing shocks during handling. Their excellent chemical resistance also makes them suitable for shipping hazardous chemicals.
Polypropylene is more rigid and durable than HDPE, though it is more expensive. It withstands continuous and repeated torsional and bending forces, making it a resilient choice for pallets.
The plastic pallet industry heavily relies on recyclable plastic materials, which vary based on the design and material composition of the recycled pallets. The main types of recycled materials used are HDPE, PP, a combination of HDPE and PP, and advanced composite material (ACM).
Various manufacturing processes are employed to produce recycled pallets, including injection molding, blow molding, foam molding, thermoforming, extrusion, and rotational molding. The selection of a specific process depends on the intended use of the pallet, the type of plastic pellets used, and the required properties to suit the application.
ACM pallets are constructed from 100% recycled plastics, primarily polyolefins (PO), which are commonly used in plastic manufacturing. These pallets are produced using a blend of industrial scrap (PIR) and post-consumer content (PCR), resulting in a durable plastic resin. ACM pallets are typically used as single-use or "send and forget" pallets. Their main appeal lies in their cost, which is comparable to that of wooden pallets.
Metal pallets, constructed from materials such as aluminum, carbon steel, and stainless steel, are utilized for transporting items like military equipment, automotive parts, food, beverages, and pharmaceuticals. These pallets are known for their strength, ability to handle heavier loads, and resistance to weathering, chemicals, and microbial contamination. Due to their robustness, metal pallets have a long service life and can be easily sanitized.
However, metal pallets are quite costly, surpassing the expense of plastic, pressed wood, and wooden pallets. They are also challenging to repair and are unsuitable for use in electrically charged environments. Additionally, their weight can contribute to higher transportation costs.
The specialized design of metal pallets caters to specific shipping requirements. Their durability makes them suitable for handling heavy, pre-assembled parts and for long-term warehouse storage of materials.
Paper pallets developed from the difficulties of packaging companies having to deal with the problems of metal and wood pallets, which were cost, weight, safety, adaptability, and disposal. Paper pallets, or corrugated pallets, are pallets made from paper board sheets or reinforced paper. Built with runners, cores, and top sheets, paper pallets are engineered to be strong and exceptionally reliable. They are safer than wood pallets since they are built without the use of nails, fasteners, staples, and never splinter.
Similar to PET plastic pallets, paper pallets are fully recyclable and comply with Occupational Safety and Health Administration (OSHA) standards. They typically weigh between 13 lbs and 16 lbs, making them about one-third the weight of traditional wooden pallets.
Paper pallets are lightweight, customizable, environmentally friendly, and easy to produce, making them a great option for shipping goods. However, they have some limitations, such as lower strength, which restricts their capacity to carry heavier loads and offer protection for products. Additionally, paper pallets are sensitive to moisture and temperature fluctuations and can be flammable if exposed to fire.
Pallets can be categorized based on various factors including their support structure, number of entry points, deck configurations, and specific features and design elements. These aspects are crucial when selecting the appropriate pallet for a given application.
The mode of support between the top and bottom deck boards is crucial to the design of a pallet. Pallets are generally classified as either stringer pallets or block pallets:
The top and bottom decks of stringer pallets are connected by longitudinal pieces known as stringers. Typically, two stringers are placed on opposite sides of the pallet, with one or two additional stringers installed in parallel to the outer ones, positioned in the middle.
Block pallets feature twelve vertical supports called blocks, which uphold the top and bottom decks. These blocks are placed at the four corners, the center of each side, and the midpoints of the pallet.
Pallets can also be categorized based on the number of entry points where handling equipment, such as forklifts or pallet jacks, can access them:
These pallets offer access from all four sides, optimizing handling efficiency by reducing loading and unloading times, which is especially useful in confined spaces. Typically, block pallets are designed as four-way pallets. While they are the most robust and can support the highest weight capacities, they are also the heaviest and most costly option.
These pallets provide access from only two of their sides. This limited entry requires handling machinery to be positioned at a specific angle or orientation to manage the pallet. Typically, stringer pallets are two-way pallets by default. However, it is possible to modify a two-way pallet into a four-way or partially four-way pallet by adding notches to the non-accessible sides. This modification allows for entry from additional sides but can compromise the pallet's strength and reduce its weight capacity compared to the original two-way design.
The top deck of a pallet is where the product is placed. Various deck configurations are available, each suited to different products and shipping conditions.
Open deck pallets, also referred to as ventilated pallets, feature a top deck with gaps or perforations. These openings reduce the pallet's weight and facilitate the drainage of liquids if the product is wet.
Solid deck pallets are designed with a continuous top deck board, lacking any gaps. This design is preferred for its hygiene and ease of cleaning, as it eliminates hard-to-reach areas. Solid deck pallets are also well-suited for transporting small items, as there are no spaces where products could fall through.
Double face pallets feature mesh or planks on both the top and bottom faces, enhancing the pallet's strength and ensuring even weight distribution. These pallets come in two variations: reversible and non-reversible. Reversible pallets have identical top and bottom decks, allowing them to be stacked with products on either side. Non-reversible pallets, on the other hand, have different configurations on each side, with the top deck typically having more planks to better support the product during placement.
Double wing pallets feature top and bottom decks that extend beyond the stringers or blocks, providing additional surface area. This design makes them suitable for transporting large or numerous items simultaneously.
CP pallets are custom-designed for the chemical industry and must comply with the Plastics European Council standards and CP specifications. The CP rating of a pallet reflects its dimensions, with sizes ranging from 29.92 inches by 44.88 inches to 44.88 inches by 44.88 inches.
The CP rating not only specifies the pallet's dimensions but also dictates the types of containers it can transport and its construction details. The different CP ratings include:
| Chemical Pallet (CP) Rating System | |
|---|---|
| Rating | Description |
| CP1 | Best for boxes and bags or sacks of raw materials - have no bottom deck board and fitted with runners. |
| CP2 | Used to transport canisters, boxes, and fiber drums - three runners. |
| CP3 | Ideally suited to transporting bags, barrels, and octabins - square with three runners. |
| CP4 | Designed for sacks of raw materials - three runners and wide lead or edge board. |
| CP5 | Made for transporting small boxes and cartons - smaller with three runners and no bottom deck. |
| CP6 | Best for sacks and boxes - has a bottom deck board. |
| CP7 | Used to transport sacks - can easily be stacked. |
| CP8 | Designed to transport sacks and octabins - square pallets with bottom deck boards with a gap in the center for drainage. |
| CP9 | Ideal for bulk containers and drums - same as CP8 without drainage hole. |
A range of features can be added to pallet designs to enhance convenience and ergonomic efficiency for shipping providers and warehouse staff. These features are particularly prevalent in plastic pallets, as they can be seamlessly integrated into the pallet during the manufacturing process.
Drum pallets are specifically designed for managing containers filled with liquids, oils, and hazardous chemicals during transport and storage. They feature a catch panel to contain leaks and spills, helping to prevent contamination of the workplace and the environment, and facilitating easier cleanup. Typically, a standard drum pallet can accommodate up to four 55-gallon drums.
Stackable pallets feature a flat, solid base that supports the stacking of products and other pallets, allowing for double stacking. This base provides enhanced stability, reducing the risk of slipping or tipping when pallets are stacked, whether they contain products or are empty. These pallets are commonly used in warehouses where diverse stacking configurations and heavy loads are common.
Nestable pallets are designed with legs that fit into the legs and top of other nestable pallets, allowing for compact stacking. This feature enables efficient storage by reducing the space needed during return trips and in warehouse storage. However, this design means that nestable pallets do not have a completely smooth, flat surface.
Rackable pallets are designed to support heavier loads with enhanced load capacity. These pallets are made from plastics through injection, rotational, or foam molding processes, which add reinforcement for handling larger weights. Typically, rackable pallets are available in the standard size of 48 x 40 inches to fit into conventional pallet racks.
To ensure a secure fit on warehouse racks, rackable pallets feature grooves or ridges on their underside and are engineered to maximize storage space utilization. Light-duty rackable pallets with specialized designs have received approval from the Federal Drug Administration (FDA) and the United States Department of Agriculture (USDA) for use with pharmaceuticals, meat, food products, and medical devices.
Pallet sizes are standardized to simplify material handling across various equipment and vehicles. These standards facilitate fair agreements and compatibility within the supply chain, thereby easing global trade. Various organizations and associations around the world regulate pallet sizes. The most widely recognized among them are:
The table below outlines the six ISO-approved pallet dimensions, which serve as standard sizes for many regions. These dimensions are specified in ISO Standard 6780:2003, which covers Flat Pallets for Intercontinental Materials Handling – Principal Dimensions and Tolerances.
| Dimensions in mm (W x L) | Dimensions in inches (W x L) | Regions most used in |
|---|---|---|
| 1016 x 1219 | 40 x 48 | North America |
| 1000 x 2000 | 39.37 x 47.24 | Europe, Asia |
| 1165 x 1165 | 45.9 x 45.9 | Australia |
| 1067 x 1067 | 42 x 42 | North America, Europe, Asia |
| 1100 x 1100 | 43.3 x 43.3 | Asia |
| 800 x 1200 | 31.5 x 47.24 | Europe |
There are pallet sizes from GMA and EPAL which were adapted and recognized by the ISO.
GMA sanctions the standard dimensions of pallets used for handling goods within North America. This standard tailor fits the pallet sizes to industry-specific needs. Some of the pallet sizes in the GMA standard have counterparts in the ISO standard.
| Dimensions in mm | Dimensions in inches | Production Rank | Industry |
|---|---|---|---|
| (W x L) | (W x L) | ||
| 1016 x 1219 | 40 x 48 | 1 | Grocery, many others |
| 1067 x 1067 | 42 x 42 | 2 | Telecommunications, Paint |
| 1219 x 1219 | 48 x 48 | 3 | Drums |
| 1219 x 1016 | 48 x 40 | 4 | Military, Cement |
| 1219 x 1067 | 48 x 42 | 5 | Chemical, Beverage |
| 1016 x 1016 | 40 x 40 | 6 | Dairy |
| 1219 x 1143 | 48 x 45 | 7 | Automotive |
| 1118 x 1118 | 44 x 44 | 8 | Drums, Chemical |
| 914 x 914 | 36 x 36 | 9 | Beverage |
| 1219 x 914 | 48 x 36 | 10 | Beverage, Shingles, Packaged Paper |
| 889 x 1156 | 35 x 45.5 | Unknown | Military ½ ISO container, fits 36" standard doors |
| 1219 x 508 | 48 x 20 | Unknown | Retail |
EPAL pallet sizes, also known as EUR pallets, are designed to comply with export specifications within the European Union. Certain pallet sizes in the EPAL standard align with those in the ISO standard.
| EURO Pallet Type | Dimensions (W x L x D) | ISO Alternative |
|---|---|---|
| EUR 1 or EUR | 800 mm × 1200 mm 31.50 in × 47.24 in |
ISO 1 |
| EUR 2 | 1200 mm × 1000 mm 47.24 in × 39.37 in |
ISO 2 |
| EUR 3 | 1000 mm × 1200 mm 39.37 in × 47.24 in |
|
| EUR 6 | 800 mm × 600 mm 31.50 in × 23.62 in |
ISO 0, half the size of EUR |
| 600 mm × 400 mm 23.62 in × 15.75 in |
quarter the size of EUR | |
| 400 mm × 300 mm 15.75 in × 11.81 in |
one-eighth the size of EUR |
International Standards for Phytosanitary Measures No. 15 (ISPM-15) is the "Regulation of wood packaging material in international trade." This set of measures, established by the International Plant Protection Convention (IPPC), aims to control the introduction and spread of invasive species through improperly processed and contaminated wood. Raw wood, whether from living or dead trees, may carry pests such as bugs and beetles, as well as pathogens. The spread of these organisms can harm biodiversity. Adopted by numerous countries worldwide since 2002, ISPM-15 is continuously updated to address these concerns.
ISPM-15 applies to wooden pallets and other packaging materials like crates and dunnage with a thickness greater than 6 mm, using coniferous softwood and non-coniferous hardwood. However, the following wooden articles, which present a low risk of pest infestation, are exempt from this standard:
Raw wood used in the construction of wooden pallets must be debarked, regardless of the treatment method employed. Debarking is essential to prevent re-infestation while the wood awaits further processing. Only small pieces of bark are permitted, specifically those less than 3 cm wide or, if wider than 3 cm, with a total surface area of less than 50 square centimeters on each piece.
Debarking should be completed prior to treatment with methyl bromide or sulfuryl fluoride, as bark can interfere with the effectiveness of these treatments. For heat treatment processes, bark may be removed either before or after the heating process.
Below are examples of various treatment methods:
Treatment procedures, conducted by authorized providers, are regulated and overseen by the national plant protection organization (NPPO) of both the importing and exporting countries.
An IPPC mark is applied by the treatment providers to treated wood to certify it has undergone the approved procedures outlined by ISPM-15. The marking consists of:
The image above shows an example of an IPPC mark, though it may appear in various forms, provided it includes all the required elements of the official mark.
Wooden pallets that have been treated according to ISPM-15 standards and have not been repaired or modified can be reused without additional treatment. However, if a third of the wooden parts are replaced with raw wood during repairs, the pallet is classified as re-manufactured and must undergo re-treatment.
Pallets constructed from plastic, metal, and paper are not subject to this regulation and do not need treatment procedures. However, regular cleaning and disinfection are essential, particularly for pallets used in handling food, beverages, agricultural products, and pharmaceuticals. For plastic pallets, cleaning methods such as high-pressure washing, power washing, and manual washing are commonly used.
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