Custom Pallet Solutions

Tailored pallets designed for your unique needs

Custom Options

Any Size

Build pallets to exact dimensions you need for optimal space utilization and product fit.

Special Features

Add custom features like drainage holes, non-slip surfaces, or reinforced corners.

Material Choice

Select specific wood types, treatments, or even mix materials for perfect application.

Design Process

Requirements Analysis

We start by understanding your specific needs including product dimensions, weight, handling equipment, storage systems, and operational environment. Detailed requirements ensure custom pallets perform exactly as needed.

Engineering Design

Our engineers design pallets optimized for your application. Structural analysis ensures adequate load capacity with efficient material use. CAD drawings provided for your approval before manufacturing begins.

Prototype Development

For complex custom designs, we can build prototype pallets for testing in your actual operation. Prototypes verify design meets requirements before committing to production quantities. Testing identifies any needed modifications.

Design Approval

Review and approve final design specifications including dimensions, materials, features, and construction methods. Clear documentation ensures manufactured pallets match expectations. Changes accommodated before production starts.

Production Planning

Manufacturing schedule coordinated with your timeline. Material procurement, production capacity allocation, and quality control procedures established. Efficient planning ensures on-time delivery of custom orders.

Ongoing Refinement

After initial production, we can refine designs based on real-world performance. Continuous improvement optimizes custom pallets for evolving needs. Long-term partnership approach ensures pallets always meet requirements.

Specifications

Precise Dimensions

Custom pallets built to exact dimensions within tight tolerances. Critical for automated systems, specific rack configurations, or optimized container loading. Precision manufacturing ensures consistent fit and function.

Load Capacity Engineering

Pallets engineered for specific load capacities including static, dynamic, and racking loads. Structural analysis and testing verify capacity. Safety margins built in for reliable performance under maximum loads.

Entry Configuration

Choose two-way or four-way entry based on handling equipment. Notched stringers, perimeter base, or block design selected for optimal compatibility. Entry dimensions customized for specific forklift or pallet jack requirements.

Deck Configuration

Top and bottom deck board spacing, width, and arrangement customized. Solid deck, gap deck, or specific patterns designed for application. Deck configuration affects product support, weight, and functionality.

Hardware Specifications

Fastener types, sizes, and placement patterns engineered for application. Nails, screws, bolts, or specialized fasteners selected based on requirements. Proper fastening critical to custom pallet performance and longevity.

Finish and Treatment

Surface finish, edge treatment, sanding, and chamfering specified as needed. Heat treatment, kiln drying, or pressure treatment selected. Paint, stain, or branding applied per requirements for appearance or identification.

Material Choices

Wood Species Selection

Choose from hardwoods (oak, maple, ash) for maximum strength or softwoods (pine, fir) for economy. Mixed wood combinations balance performance and cost. Species selected based on load requirements and budget.

Grade Options

Lumber grade affects appearance, strength, and cost. Premium grades for visible applications, standard grades for typical use. Grade selection matches application requirements without overspending on unnecessary quality.

Engineered Wood Products

Plywood, OSB, or laminated veneer lumber (LVL) provide consistent properties and smooth surfaces. Ideal for specific applications requiring uniform characteristics. Engineered products offer alternatives to solid wood.

Alternative Materials

Plastic, metal, or composite materials available for applications where wood unsuitable. Material selection based on environment, cleanliness requirements, durability needs, or regulatory compliance. We source materials meeting specifications.

Reclaimed and Recycled

Recycled lumber or plastic reduces costs and environmental impact. Suitable for applications where virgin materials unnecessary. Recycled content supports sustainability goals while maintaining functionality.

Specialized Components

Custom hardware, corner protectors, edge treatments, or integrated features specified. Specialized components enhance functionality for unique applications. Sourcing and integration handled as part of custom manufacturing.

Load Testing

Static Load Testing

Pallets tested under full static load to verify capacity when sitting on flat surface. Testing ensures adequate strength for stacking and floor storage. Static capacity highest rating for pallet strength.

Dynamic Load Testing

Testing simulates forklift handling and movement. Dynamic capacity typically 50-60% of static capacity. Ensures pallets withstand transportation and handling stresses without failure.

Racking Load Testing

Pallets tested supported only at edges simulating warehouse racking. Most demanding test with lowest capacity. Critical for applications requiring reliable racking performance. Prevents dangerous failures in rack systems.

Durability Testing

Repeated loading cycles test long-term durability and fatigue resistance. Identifies potential weak points before production. Ensures custom pallets maintain performance throughout expected service life.

Environmental Testing

If needed, testing under temperature extremes, moisture, or chemical exposure. Verifies performance in challenging environments. Specialized testing ensures reliability in harsh conditions.

Documentation and Certification

Complete test reports document pallet performance. Certifications provided if required by customer or industry standards. Testing documentation supports quality assurance and regulatory compliance.

Lead Times

Design Phase

Initial design and engineering typically 1-2 weeks depending on complexity. Includes requirements gathering, engineering, and design approval. More complex projects may require additional time for proper development.

Prototype Production

If prototypes needed, add 1-2 weeks for manufacturing and testing. Allows validation before full production. Prototype phase optional for simple designs or rush projects.

Material Procurement

Standard materials available quickly. Specialized materials, treatments, or components may require 2-4 weeks lead time. Early identification of long-lead items prevents delays.

Production Time

Manufacturing typically 2-4 weeks depending on quantity and complexity. High volumes or specialized features extend production time. Scheduling coordinated with your delivery requirements.

Expedited Service

Rush production available for premium when schedule critical. Expediting may require overtime or priority scheduling. Most custom orders can be accelerated if necessary.

Total Project Timeline

Complete custom pallet project typically 4-8 weeks from concept to delivery. Simple designs at low end, complex projects at high end. Clear timeline provided upfront with milestones tracked.

Custom Applications

Automated Systems

Precise tolerances and consistent dimensions critical for automated warehouses. Custom pallets engineered for conveyors, sorters, and AS/RS systems. Reliability in automation prevents costly system jams and downtime.

Specialized Industries

Aerospace, automotive, pharmaceutical, and other industries have unique requirements. Custom pallets meet stringent specifications and regulatory requirements. Industry expertise ensures compliance and optimal performance.

Export Optimization

Pallets sized to maximize container utilization reducing shipping costs. Dimension optimization can fit additional units per container. ISPM 15 compliance integrated as needed for international shipping.

Heavy-Duty Applications

Reinforced construction for extremely heavy or concentrated loads. Engineering and testing verify capacity for demanding applications. Heavy-duty pallets prevent failures and damage in industrial environments.

Clean Room and Sanitary

Smooth surfaces, sealed edges, and washable finishes for pharmaceutical or food applications. Materials selected for sanitary compliance. Custom features support stringent cleanliness requirements.

Display and Retail

Attractive appearance, branded surfaces, and specialized configurations for retail environments. Display pallets enhance product presentation. Custom designs create competitive advantage at point of sale.

Custom Pallets FAQ

What is the minimum custom order?

Prototype runs can start at 25 units before scaling to full production.

How does the design process work?

Share your product specs, and our engineers create drawings for approval.

Can you match an existing sample?

Yes, we reverse-engineer legacy pallets or follow supplied CAD files.

Do you provide prototypes?

Physical prototypes and CAD renderings are provided so teams can test fit and capacity.

How long do prototypes take?

Simple builds finish within a week, and complex designs may need two weeks including testing.

What materials can be used?

Hardwood, softwood, plywood, composites, or hybrid assemblies are available.

Can custom pallets be heat treated?

Yes, any approved design can be heat-treated and stamped for export.

Do you perform load testing?

We run static, dynamic, and rack tests to confirm the pallet meets your requirements.

How are pallets packaged for shipment?

Custom builds are banded, wrapped, and labeled by project so they stay organized.

How is pricing calculated?

Material, hardware, labor complexity, and testing requirements drive the project estimate.