Plastic Pallets
Plastic pallets are sturdy platforms designed for the storage and transportation of products. The terms "plastic pallet" and "plastic skid" are used interchangeably, and you will frequently encounter both terms in pallet descriptions across various industries.
Applications of Plastic Pallets
Plastic pallets are designed for the storage and transportation of products and goods across a wide range of industries. They are highly valued for their strength, durability, and chemical resistance, making them a reliable choice for warehouses, factories, shipping companies, and various other businesses that depend on efficient material handling.
Their unique properties make them particularly useful in diverse applications. Due to their high hygiene and sanitation levels, and because they do not pose a risk of cross-contamination, plastic pallets are essential in industries involved in the production and shipment of consumable goods. This includes agriculture, food service, beverage production, pharmaceuticals, and medical equipment manufacturing. Additionally, they play a crucial role in the storage and transport of hazardous industrial chemicals and are widely used in the material handling, packaging, automotive, and postal service industries.
The History of Plastic Pallets
Pallets Before Plastic
For centuries, wood was the dominant material for pallet and skid construction. However, wooden pallets are highly susceptible to splintering, breakage, contamination from pathogens like E. coli, fire hazards, and overall wear and tear. Most wooden skids become unusable within two years, limiting their long-term reliability.
The use of wooden pallets and skids dates back thousands of years, with records indicating their presence as early as the 1st millennium BC. However, little documentation exists regarding their role in early modern history. The modern pallet emerged in the 1920s, with Howard T. Hallowell receiving the first U.S. pallet patent in 1924 for his "Life Truck Platform." By the 1930s, pallet designs evolved alongside new forklift technologies, improving efficiency in material handling.
A major turning point for pallets came with World War II, when they became essential in military logistics and production operations. During this period, metal pallets—particularly steel pallets—were introduced for heavy-duty applications, offering greater durability than their wooden counterparts.
Plastic Enters the Scene
Throughout the following decades, companies like Robison Industries began experimenting with plastic pallets, using thermoforming techniques to create reusable alternatives to traditional wooden models. Plastic pallets first gained mainstream recognition in the 1960s, and one of the earliest known commercial references appeared in 1964, when Modern Materials Handling Magazine mentioned fiberglass-reinforced plastic pallet containers. Early plastic pallets were produced using thermoformed twin sheets and injection molding techniques.
By the early 1970s, more manufacturers entered the plastic pallet industry, expanding its application into fields such as automotive, food, and pharmaceutical processing. Despite their advantages, wooden pallets remained the preferred choice for most businesses due to their lower cost and widespread availability.
A significant shift occurred in the early 2000s with the introduction of ISPM 15 (International Standards for Phytosanitary Measures No. 15). These global regulations, adopted between 2004 and 2010, imposed strict treatment standards on wooden products crossing international borders, including crates and pallets, to prevent the spread of pests and diseases. As compliance with these standards became more expensive, many companies turned to plastic pallets, which were exempt from phytosanitary regulations and offered a cost-effective alternative for international shipping.
The Future of Plastic Pallets
The environmental impact of plastic pallet production remains a complex issue. Wooden pallets require vast quantities of lumber, and because they have short lifespans, the demand for wood is continuous and unsustainable. In contrast, plastic pallets are derived from petrochemicals, and their extraction, processing, and refinement contribute significantly to environmental degradation and geopolitical instability.
If wooden pallets were phased out entirely, plastic pallets would likely replace them, leading to increased demand for raw plastic, refined petrochemicals, and crude oil. However, plastic pallets offer the advantage of reusability and recyclability, features not typically found in wooden pallets.
As plastic technology and recycling methods continue to advance, manufacturers and businesses must take responsibility for maximizing the lifespan of plastic pallets and ensuring proper recycling and disposal. Responsible use and material innovation will be crucial in mitigating the environmental impact of widespread plastic pallet adoption in the future.
Advantages of Plastic Pallets
Plastic pallets have become a preferred choice among manufacturers and shippers, thanks to continuous design improvements that have enhanced their performance over the years. While wood pallets are still widely used for storage and transportation due to their convenience and availability, plastic pallets are rapidly gaining market dominance. Their numerous advantages make them an increasingly attractive alternative.
Working Life
Plastic pallets provide a level of durability that wood pallets simply cannot match. They are resistant to moisture, water, and other weather-related conditions that often degrade wooden pallets. Industry experts estimate that plastic pallets last up to ten times longer than their wood counterparts. In closed-loop distribution systems, where they are used under normal handling and loading conditions, plastic pallets can remain functional for as long as ten years.
Cost and Longevity
While plastic pallets do have a higher upfront cost compared to traditional wooden pallets, their durability and long lifespan make them a cost-effective investment. Unlike wood, plastic pallets do not require frequent repairs or replacements, significantly reducing long-term expenses. Their reusability across multiple years and applications makes them a valuable asset for businesses looking for efficiency and sustainability in material handling.
Environmental Friendliness
One of the key benefits of plastic pallets is their contribution to environmental sustainability. Increased demand for plastic pallets reduces reliance on wood, which is often sourced from forests, contributing to deforestation. Since deforestation is a major driver of global warming, shifting towards plastic pallets helps minimize the impact on natural resources while promoting long-term environmental responsibility.
Plastic Recyclability
Unlike wood pallets, which cannot be reused once they deteriorate, plastic pallets can be recycled and repurposed at the end of their service life. Recycling plants melt down discarded plastic pallets and reshape them to meet new size and shape specifications. This capability makes plastic pallets a more sustainable and cost-effective solution, as businesses can reduce waste and avoid constant pallet replacements.
Plastic Sterility
Plastic pallets offer superior protection against contamination compared to wooden pallets. Unlike wood, which is porous and can harbor moisture, bacteria, and mold, plastic is a non-porous material that does not provide hiding spots for harmful microorganisms. A National Consumers League survey on perishable product shipments found that 10% of wooden pallets were contaminated with E. coli and Listeria, whereas only 1.4% of plastic pallets showed contamination. The synthetic composition of plastic makes it an ideal choice for high-humidity environments and industries requiring strict sanitation standards, such as food, pharmaceuticals, and healthcare.
Plastic Pallet Design
Production Process
Plastic pallets are manufactured using a variety of industrial processes, including injection molding, compression molding, and thermoforming. These techniques produce pallets that are durable, strong, and cost-effective. Additionally, manufacturers can reuse and reshape old plastic pallets to create new ones, making the process more sustainable and resource-efficient.
Material Process
Most plastic pallets are made from new HDPE (high-density polyethylene) or PET (polyethylene terephthalate), which is often recycled from drink bottles. HDPE is the most commonly used material due to its resistance to corrosion and chemical exposure, ensuring it remains unaffected by substances like acetone and calcium sulfate. It is also easy to clean, making it an ideal choice for industries requiring hygienic storage and transport solutions.
PET, or polyester, provides an excellent barrier against water, moisture, and gases, making it highly effective for certain shipping applications. Though PET pallets are lightweight, using recycled PET can be more expensive due to the extensive cleaning required. In general, the plastics selected for pallet manufacturing are non-porous, resistant to extreme temperatures, and inhospitable to harmful organisms, ensuring they meet high standards for durability and sanitation.
Design Customization
While manufacturers produce a wide range of standard plastic pallets, they must ensure each pallet is capable of bearing loads without breaking, slipping, or shifting during storage or transport. Additionally, pallets must be designed for compatibility with forklifts, hi-lows, and pallet jacks, facilitating easy movement within warehouses and seamless loading and unloading during shipping.
Custom plastic pallets are also widely used. When designing a custom pallet, manufacturers focus on optimizing storage and shipping efficiency for specific applications. They consider requirements such as stackability, rackability, nestability, unique storage needs, and industry standards. Custom pallets can also be tailored to fit regional sizing norms, such as the European size pallet, which differs significantly from the American standard pallet, ensuring compatibility with various international shipping and logistics systems.
Plastic Pallet Features
Most plastic pallets are designed for full accessibility, allowing them to be lifted from all sides, with some even capable of being lifted at their angles. This versatility is made possible by a strategic array of nine feet or legs positioned at the corners, sides, and center of the pallet. The inherent sturdiness of plastic ensures that as long as the load weight is within the pallet’s capacity, there will be no bending, shifting, or structural compromise. Additionally, plastic pallets boast a higher strength-to-weight ratio than wooden pallets, meaning a lighter plastic pallet can often support a greater load weight than a heavier wooden counterpart.
Unique Characteristics
One of the most significant advantages of plastic pallets over wooden pallets is their extended service life—lasting up to five times longer than the average wooden pallet. Used plastic pallets can remain in operation for years without showing significant wear or structural degradation. When they do reach the end of their usable lifespan, they can be recycled and reprocessed into new pallets or other plastic products, ensuring minimal waste. Additionally, some companies specialize in reselling used plastic pallets that still have a substantial remaining service life, further enhancing their sustainability and cost-effectiveness.
Plastic Pallet Types
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Custom Pallets
Designed to accommodate special requirements for size, handling, and storage.
Drum Pallets
Specifically designed to transport or store multiple drums, typically two or four, with circular recessed grooves molded into the top for secure placement. Drum pallets help contain hazardous or messy chemicals, preventing spills that could cause environmental damage or workplace safety hazards. They act as containment basins, capturing leaks from drum loads.
Euro Pallets
Also known as EU pallets or E pallets, these are designed to meet the pallet standards of the European Union. They are required for trading goods overseas to the EU.
Export Pallets
Used for shipping products internationally, these pallets are traditionally made of wood.
Nestable Pallets
Designed to fit tightly into one another when empty, maximizing storage space. They "nestle" together for easy stacking and transport.
Wooden Pallets
Traditional pallets made of wood, used as platforms for transporting and storing products.
Plastic Crate Pallets
Feature walls or a basket-like structure to stabilize and contain products more securely.
Plastic Racking Pallets
Designed for placement on pallet racks for organized storage.
Plastic Shipping Pallets
Used for stacking and transporting products or materials efficiently.
Plastic Skids
Pallets equipped with wheels for easier mobility and maneuverability.
Rackable Pallets
Built to be supported on their edges for long periods, either along the width or length. These pallets are designed to fit securely onto storage racking beams until removed by forklifts or pallet jacks.
Recycled Pallets
Refers to two aspects of plastic pallets: first, they are highly durable and can be recycled easily; second, they can be manufactured from recycled plastic materials.
Platforms used in packaging to securely hold goods for transportation.
Spill Containment Pallets
Also known as spill pallets, these pallets ensure that any leaked, dripped, or spilled materials remain contained, preventing environmental contamination. They are commonly used for drums and IBC totes.
Stackable Pallets
Feature closed bottom decks, allowing them to be securely stacked when fully loaded. Their flat, uniform bottoms ensure stable stacking.
Used Plastic Pallets
Previously used for shipping or storage but still in working condition, offering a cost-effective and sustainable option.
Export Pallets
Used for international shipping, these pallets have largely replaced wooden export pallets due to their lower cost and faster production.
Standards and Specifications for Plastic Pallets
All plastic pallets must comply with strict shipping condition standards. In the United States, the Food and Drug Administration (FDA) regulates consumer product handling procedures to ensure safety and hygiene. Consumer advocacy organizations like the National Consumers League conduct surveys on pallets in circulation, testing them for contamination to uphold public health standards. If you intend to use plastic pallets for exports, it is essential to verify that they meet the specific regulations and requirements of the destination countries or regions to ensure compliance and avoid shipping delays.
Things to Consider When Purchasing Plastic Pallets
Choosing Your Pallet Type
Carefully consider the intended use of the pallets before making a selection. Plastic pallets are ideal for environments where products must be kept clean and free from moisture, which is why they are widely used in the food, beverage, and pharmaceutical industries.
Take into account the weight of the products that will be placed on the pallets. Before deciding between plastic, metal, or wood pallets, determine the load capacity required. Industry experts recommend plastic pallets for loads up to 1,500 pounds. For heavier loads, wood pallets are often the more practical choice due to their higher weight tolerance.
Consider the environmental impact of both wood and plastic. While wood itself does not pose a direct environmental threat, deforestation is a major contributor to climate change, making it important to reduce dependence on wood-based manufacturing materials. On the other hand, improperly discarded plastic can cause severe environmental harm, though it is recyclable, whereas wood pallets cannot be repurposed after deterioration.
If you require pallets that can support your products while maintaining a clean and professional warehouse environment, plastic pallets are an excellent choice. Their customizable design options allow for tailored solutions based on specific needs.
Choosing a Manufacturer
Selecting the right pallet material may be straightforward, but finding the best manufacturer can be more challenging. To simplify the process, we have provided a comprehensive list of reputable and experienced plastic pallet manufacturers near the top of this page
To make an informed decision, start by browsing their websites to get a sense of their products and services. Identify three to four manufacturers that best align with your needs and reach out to them to discuss your specifications. When speaking with potential suppliers, be sure to ask about industry certifications, lead times, pricing, and delivery options.
After gathering this information, compare their responses, customer service quality, and overall offerings. Choose the manufacturer that not only provides the best product but also offers exceptional support and reliability.
Proper Care for Plastic Pallets
Plastic has a smooth, non-porous surface that allows for easy cleaning with a vacuum cleaner or a water stream. Unlike other pallet materials, plastic requires no additional arrangements or special treatments for cleaning and maintenance, making it a hygienic and low-maintenance option for various industries.
Plastic Pallet Accessories
Depending on your application, recommended accessories include a pallet cover, row spacers, RFID labeling, no stack pallet cones, pallet liners, and other pallet packaging solutions to enhance functionality and protection during storage and transport.
Plastic Pallet Terms
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Automatic Palletizers
Assemble products on pallets independently or with minimal assistance, often functioning as part of a larger shipping system.
Bag Palletizers
Designed with specialized gripping modifications to arrange bags on pallets for shipping and transportation; may be in-line or robotic.
Blue Palletizers
A pallet with its sides painted blue, signifying ownership by the rental company CHEP.
Captive Pallet
A pallet that remains within a facility and is not exchanged, traded, or transported off-site.
Corrugated Plastic
A material, typically extruded from polypropylene, featuring fluted construction similar to corrugated board. It is waterproof, durable, chemical-resistant, and available in a variety of transparent and translucent colors with a strong strength-to-weight ratio.
Corrugated Pallets
Lightweight pallets made from corrugated cardboard, corrugated fiberboard, laminated paperboard, or paperboard composite honeycomb. These pallets weigh 65% to 75% less than their wood or plastic counterparts and include structural reinforcements and forklift blade spacers.
Deck
The side of a pallet that faces either upward or downward.
Eight-Way Pallet
A pallet allowing forklift entry on all four sides as well as diagonally at each corner.
Fork Entry
The designated space for forklift forks to move the pallet, typically between decks or beneath the top deck.
Four-Way Pallet
A pallet that permits forklift entry from all four sides.
Hygienic
Promoting health and sanitation.
Manual Palletizers
Assist in stacking goods onto a pallet and aid with layer organization for efficient handling.
Nesting
The capability of containers of different sizes to be placed inside one another to save space.
Non-Reversible Pallet
A pallet that cannot be used upside down, either because it lacks bottom boards or has a limited number of bottom boards.
One-Way Pallet
A pallet made from low-quality materials, intended for a single shipment and disposal.
Orange Pallet
A pallet with its sides painted orange, indicating it belongs to the Canadian Pallet Council pallet pool.
Racked Across Deckboards
The maximum load capacity and deflection of a pallet when the rack frame supports the pallet at the ends of the deckboards.
Racked Across Stringers
The maximum carrying capacity of a pallet when the rack frame supports it only at the ends of the stringers or stringer boards.
Reversible Pallet
A pallet with identical deck boards on both the top and bottom, allowing it to be used in either orientation.
RFID (Radio Frequency Identification)
A tracking device ranging from tiny labels to paperback book-sized transmitters, capable of storing more data than barcodes. It does not require line-of-sight scanning and performs effectively in harsh environments.
Rotationally Molded Plastics
A common plastic pallet manufacturing method, producing strong, seamless, and customizable pallets.
Skid
A pallet without bottom boards, also referred to as a single-deck pallet.
Slave Pallet
A panel used to support the base of a palletized load in rack-storage facilities.
Stringers
The boards positioned between the top and bottom deck boards of a pallet.
Two-Way Pallet
A pallet allowing forklift entry from only two opposite ends.
Unit Load
A collection of goods grouped together on a pallet for movement or shipping.
White Pallet
A pallet not painted or marked to indicate ownership.
