Which Plastic Pallets Should You Choose?

What Makes Plastic Pallets Different?

Plastic Pallets offer consistent dimensions, moisture resistance, and cleanability that reduce product damage and downtime. They are designed for repeat use in warehousing, production, and distribution, with options tailored to racking, hygiene, and automation needs.

Key Advantages at a Glance

• Consistent weight and size for conveyors and palletizers

• No nails, splinters, or moisture absorption

• Wash-down friendly for food and pharmaceutical environments

• Long service life that can lower total cost per trip

What Size Plastic Pallets Fit Your Flow?

Choosing the right footprint ensures compatibility with racks, trailers, and containers.

Common Footprints

• 48×40 in: Widely used in North America for retail and CPG

• 1200×1000 mm: Popular in Asia/UK for mixed goods and export

• 1200×800 mm (Euro): Common for EU fast-moving products

• 1140×1140 mm: Frequent in beverage and shipping containers

Which Type of Plastic Pallets Matches Your Use Case?

Select the platform style based on how you store and move goods.

Nestable, Stackable, or Rackable?

• Nestable: Lightweight, one-way or return flows with limited storage space

• Stackable: Solid bases for stable floor stacking and block stacking

• Rackable: Reinforced runners for beam racks; verify racking load ratings

How Much Weight Can Plastic Pallets Handle?

Always check three load ratings and test standards to prevent failures.

Load Ratings You Must Confirm

• Static Load: On a solid floor or when stacked

• Dynamic Load: During forklift or pallet jack movement

• Racking Load: On beam racks; often the lowest rating and most critical

Which Material is Best: HDPE, PP, or Recycled Blends?

Material choice affects stiffness, impact resistance, and temperature tolerance.

Material Guide

• HDPE: Excellent impact resistance and low-temp toughness (ideal for cold rooms)

• PP: Higher stiffness and heat resistance (better for racking at elevated temps)

• Recycled Compounds: Lower cost and footprint; confirm consistent performance

What Deck and Runner Options Should You Consider?

Deck and runner design influence hygiene, airflow, and load stability.

Deck Styles

• Open Deck: Lighter weight, better drainage and airflow

• Closed Deck: Smooth, easy-to-clean surface for hygiene-critical zones

Runner Configurations

• 3-Runner (longitudinal): Common for racking and conveyors

• Perimeter/5-Runner: Enhanced stability on automated equipment

• Anti-Slip Strips and Lips: Reduce load shifting during handling

Do Plastic Pallets Work in High Hygiene Operations?

Yes. Smooth, non-porous surfaces support sanitation protocols and contamination control.

Hygiene Features to Look For

• Closed decks without rib traps

• Rounded edges that shed debris

• Wash-down compatibility (temperature and detergent ratings)

Are Plastic Pallets Ready for Automation?

Uniform geometry reduces jams on conveyors, stretch wrappers, shuttles, AGVs, and palletizers.

Automation-Ready Details

• Chamfered fork entries for repeatable picks

• High-contrast surfaces for machine vision

• Label and RFID pockets for tracking and pooling

How Do Temperature and Chemicals Affect Performance?

Environment drives material choice and lifetime expectations.

Environmental Considerations

• Cold Storage: Impact-modified HDPE resists brittleness

• Heat Exposure: PP blends maintain stiffness near warm process areas

• Chemicals: Verify compatibility with acids, alkalis, and sanitizers

What Does Ownership Really Cost?

Unit price is only one piece of the puzzle; evaluate the entire lifecycle.

Total Cost of Ownership Factors

• Cycle Life and Breakage Rate

• Freight and Backhaul (weight and nestability)

• Downtime from jams or damaged decks

• Cleaning and compliance effort

• End-of-life buyback or recycling options

How to Choose Plastic Pallets Step-by-Step

Follow a simple framework to match product, process, and environment.

Selection Checklist

• Footprint aligned to racks, trailers, and containers

• Static, dynamic, and racking loads with safety margins

• Deck style (open vs. closed) per hygiene and product type

• Runner layout (3-runner, perimeter, or reinforced)

• Material (HDPE vs. PP vs. recycled) for temperature and stiffness

• Anti-slip, lips, and edge details for load retention

• Tracking (barcode/RFID) for pooling and inventory control

Common Mistakes to Avoid

Prevent avoidable failures and unplanned costs by addressing these early.

Pitfalls and Fixes

• Underrated Racking Load: Confirm beam spacing and reinforcement

• Ignoring Automation Specs: Test on conveyors and wrappers before rollout

• Overlooking Temperature Limits: Match material to cold or hot zones

• Skipping Inspection: Replace cracked runners to protect product and equipment

FAQs About Plastic Pallets

Are Plastic Pallets acceptable for export?

They typically bypass ISPM-15 requirements, reducing delays and treatments associated with solid wood.

Can Plastic Pallets be repaired?

Modular designs allow localized repairs; monobloc designs are usually replaced. Ask about repair kits and spare parts.

Will Plastic Pallets slip on forklift tines?

Textured runners, anti-slip strips, correct tine spacing, and slight mast tilt help maintain grip.

Do Plastic Pallets sag in racks?

Choose rackable models with reinforced runners and follow the rated racking load and beam spacing.

Bottom Line

Choose Plastic Pallets by matching footprint, load ratings, material, and deck/runner designs to your actual workflow. The right selection delivers durability, cleanliness, and predictable handling from production through distribution—often lowering total cost over the pallet’s lifetime.