Custom Pallets
Can't find the right pallet off the shelf? We design and manufacture custom pallets tailored to your exact requirements — any size, any material, any load capacity. From one-off prototypes to high-volume production runs, our engineering team works directly with you to build the perfect pallet for your application.
Request Custom Quote
Describe your specifications and we'll build it. Most quotes returned within 24 hours.
How It Works
Our proven six-step process ensures every custom pallet meets your exact specifications, from initial consultation through final delivery and ongoing support.
Initial Consultation
We start with a thorough consultation to understand your application. Share your product dimensions, weight distribution, shipping method, storage environment, handling equipment, and any regulatory requirements. Our team asks the right questions so nothing is overlooked — including factors you may not have considered, like climate exposure or automated system compatibility.
Engineering & Design
Our pallet engineers design the optimal solution using structural analysis and decades of industry experience. We evaluate material options, fastener types, board thickness, stringer or block configurations, deck spacing, and chamfer profiles. You receive detailed drawings with dimensions, load ratings, and material specifications for your approval before manufacturing begins.
Material Sourcing
We source the ideal materials for your build — new kiln-dried lumber, recycled hardwood, engineered plywood, plastic, or composites. Our extensive supplier network lets us find the best combination of performance, cost, and sustainability. For ISPM-15 export pallets, we source pre-treated lumber or schedule heat treatment at our certified facility.
Prototype & Approval
For new designs or complex requirements, we build a prototype pallet for your hands-on evaluation. Test it with your product, run it through your conveyor systems, and stack it on your racking. We incorporate your feedback and make adjustments before committing to a full production run. This step eliminates costly surprises.
Production & Quality Control
Once the design is locked in, our manufacturing team builds your pallets with precision. Every unit is assembled using pneumatic nailing, with consistent board placement and fastener patterns. In-line quality checks verify dimensions, fastener depth, and structural integrity. Random samples are pulled for load testing to confirm rated capacities.
Delivery & Ongoing Support
Finished pallets are inspected one final time, bundled or stacked for efficient transport, and delivered directly to your facility on your schedule. We offer recurring delivery programs for ongoing needs, can warehouse inventory on your behalf, and provide reorder support to keep your supply chain running without interruption.
Custom Options
Every aspect of your pallet can be engineered to your specifications. Here are the customization categories we work with most frequently.
Custom Dimensions
Any length, width, and height — from miniature 12"x12" retail display pallets to oversized 120"x60" industrial platforms. We build to the nearest quarter inch. Non-standard shapes including L-shaped, T-shaped, and triangular pallets are available for specialized machinery and odd-shaped loads.
Load Capacity Engineering
Every custom pallet is engineered for your specific weight requirements. We calculate dynamic loads (in motion), static loads (at rest), and racking loads (on shelving) independently. Static loads up to 15,000 lbs, dynamic loads up to 8,000 lbs, and racking loads up to 5,000 lbs are achievable depending on design and materials.
Entry Configuration
Choose between 2-way entry (stringer design, forklift access from two sides), partial 4-way entry (notched stringers for pallet jack access on all sides), or full 4-way entry (block design for unrestricted access). Entry configuration impacts warehouse efficiency, loading speed, and equipment compatibility.
Deck Board Layout
Specify top and bottom deck configurations including the number of boards, board width, spacing gaps, and whether you need a solid (no-gap) top deck. Closer spacing supports small items and prevents product fall-through. Solid decks are ideal for bags, drums, and irregularly shaped cargo.
Material Selection
Choose from hardwoods (oak, maple, birch), softwoods (pine, spruce, fir), engineered plywood, OSB, plastic lumber, recycled HDPE, or composite materials. Mix materials within a single pallet — for example, hardwood stringers with softwood deck boards — to optimize cost and performance.
Heat Treatment (ISPM-15)
ISPM-15 certified heat treatment for international shipping compliance. Pallets are heated to a core temperature of 56 degrees Celsius for a minimum of 30 minutes, then stamped with the official IPPC mark. Required for wood pallets crossing international borders. We maintain full chain-of-custody documentation.
Chemical & Moisture Treatment
Methyl bromide fumigation (where permitted), anti-mold treatments, moisture-resistant coatings, and vapor barrier wraps. Critical for pallets used in pharmaceutical, food-grade, or high-humidity environments. We also offer fire-retardant treatments for pallets stored in environments with strict fire codes.
Branding & Identification
Add your company logo, color coding, barcode labels, RFID tags, QR codes, or identification numbers. Available methods include burn stamps (permanent), stencil painting, hot branding, ink stamping, and adhesive labels. Branding helps with pallet tracking, asset management, and return programs.
Fastener Specification
Choose between ring-shank nails (standard), screw-shank nails (higher withdrawal resistance), wood screws (maximum holding power), or bolted connections (for repairable/disassemblable pallets). Stainless steel fasteners are available for corrosion-prone environments. Fastener pattern and density are customized per load requirements.
Runner & Skid Options
Add bottom runners, anti-slip pads, rubber feet, or plastic skids to prevent movement during transport. Runners protect floors from damage and enable smoother dragging. Anti-slip surfaces made from textured rubber or applied grit coatings keep loads secure on inclines and during vehicle acceleration and braking.
Collar & Sidewall Integration
Design pallets with built-in collars, side walls, or corner posts for containment. Hinged wooden collars can be folded flat when not in use. Permanent side rails prevent product shifting. Integrated corner posts enable secure vertical stacking. All containment options are customized to your product dimensions.
Automation Compatibility
Pallets engineered to work flawlessly with automated warehouse systems — AS/RS (Automated Storage and Retrieval Systems), conveyor lines, robotic palletizers, and AGVs (Automated Guided Vehicles). We verify dimensional tolerances, deflection limits, and surface friction requirements against your specific equipment specifications.
Material Selection Guide
Choosing the right material is the single most important decision in custom pallet design. Each material offers a different balance of strength, weight, cost, and environmental impact.
| Material | Strength | Weight | Cost | Durability | Best For | Limitations |
|---|---|---|---|---|---|---|
| Oak (Hardwood) | Excellent | Heavy | $$$$ | Very High | Heavy-duty, repeated use, racking | Heavier to handle, higher cost |
| Maple (Hardwood) | Excellent | Heavy | $$$$ | Very High | Pharmaceutical, food, clean rooms | Premium pricing, limited supply |
| Pine (Softwood) | Good | Light | $$ | Moderate | One-way shipping, light loads | Less durable under heavy loads |
| Spruce (Softwood) | Good | Light | $$ | Moderate | General warehouse, standard use | Susceptible to moisture damage |
| Plywood / OSB | Very Good | Medium | $$$ | High | Solid-deck pallets, export | Cannot be easily repaired |
| Recycled HDPE Plastic | Very Good | Medium | $$$$$ | Extremely High | Wet environments, food/pharma | Higher upfront cost, not repairable |
| Composite / Presswood | Good | Light | $$$ | Moderate | Export (ISPM-15 exempt), one-way | Cannot be repaired or modified |
| Mixed (Hardwood + Softwood) | Very Good | Medium | $$$ | High | Cost-optimized multi-use pallets | Requires careful engineering |
Not Sure Which Material Is Right?
Our engineers evaluate your application, budget, load requirements, and environmental conditions to recommend the ideal material or material combination. In many cases, a mixed-material approach — such as hardwood stringers with softwood deck boards — provides the best performance-to-cost ratio. We will never over-specify materials when a more economical option meets your needs.
Engineering & Structural Specs
Every custom pallet we build is backed by real engineering. Here are the structural parameters we design around.
Load Capacity Ratings
We calculate three independent load ratings for every custom pallet. Dynamic load capacity (weight while in motion on a forklift or pallet jack) typically ranges from 1,500 to 8,000 lbs. Static load capacity (weight while stationary on a flat surface) is generally 2x the dynamic rating, ranging from 3,000 to 15,000 lbs. Racking load capacity (weight while supported only at the edges on pallet racking) is typically 60-75% of the dynamic load. All ratings include standard safety margins per NWPCA guidelines.
Deflection Standards
Maximum allowable deflection under rated load is critical for racking applications and automated systems. We design to a maximum center deflection of 0.5 inches under full racking load, or tighter tolerances for AS/RS and conveyor applications (typically 0.25 inches or less). Deflection testing is performed on prototypes using calibrated equipment and documented for your records.
Fastener Specifications
Standard builds use 2.25-inch to 3.5-inch ring-shank nails driven pneumatically at 80-120 PSI. Each joint receives a minimum of two fasteners, with high-load joints receiving three or more. Screw-shank nails provide 15-25% greater withdrawal resistance for pallets subject to vibration. All fasteners are countersunk flush to prevent product damage. We maintain torque and pull-out test data for all fastener types.
Board & Stringer Dimensions
Deck board thickness ranges from 3/8 inch (light duty) to 1-1/8 inch (extreme heavy duty), with 5/8 inch and 3/4 inch being most common. Board widths from 3.5 inches to 7.5 inches are stocked. Stringer dimensions range from 2x3 inches (light duty) to 4x6 inches (ultra heavy duty), with 2x4 and 3x4 being standard. Block pallets use 3.5-inch to 5.5-inch solid or laminated blocks.
Moisture Content Control
Lumber moisture content is controlled to between 19% and 25% for standard applications and below 19% for kiln-dried builds. Low moisture content reduces pallet weight, minimizes warping and shrinkage, and prevents mold growth. For heat-treated export pallets, core temperature reaches 56 degrees Celsius for 30+ minutes, which also reduces moisture content. We monitor moisture with pin-type meters during production.
Dimensional Tolerances
Standard dimensional tolerance is plus or minus 1/8 inch on length, width, and height for wood pallets. Tighter tolerances (plus or minus 1/16 inch) are available for automated system applications at additional cost. Plastic and composite pallets are molded to plus or minus 1/32 inch tolerance. Every production run includes random dimensional audits to ensure consistency across the entire order.
Design Considerations
Building the right pallet means thinking beyond dimensions. Here are the critical design factors we evaluate for every custom project.
Load Distribution Analysis
How your product sits on the pallet determines the structural requirements. Concentrated point loads (like machinery) require reinforced stringers and closer deck board spacing directly under the contact points. Uniformly distributed loads (like boxed goods) allow wider spacing and thinner boards. We analyze your product weight map to place material exactly where it is needed — no over-building, no weak spots.
Stacking & Vertical Load
If pallets will be stacked on top of each other (floor stacking), the bottom pallet must support the cumulative weight of all pallets above it. We calculate compression loads on stringers and blocks, and design bottom decks with sufficient bearing area. For high-stack applications (4+ pallets), we may recommend block pallets or reinforced stringer designs with additional center stringers.
Handling Equipment Compatibility
Pallet design must match the handling equipment in your facility. Standard forklifts require 3.5-inch minimum opening height for fork entry. Pallet jacks need smooth bottom boards or open bottoms for roller clearance. Clamp trucks require specific side profiles. We verify that your custom pallet is compatible with every piece of handling equipment in your supply chain — from your dock to your customer.
Racking System Requirements
Pallets used in racking systems face unique structural demands because they are supported only at the edges. The unsupported span in the middle must resist deflection under full load. We design for your specific rack beam spacing, verify that the pallet overhang is within safe limits (typically 2-3 inches per side), and ensure bottom boards align with rack beams for maximum support.
Transportation & Shipping Factors
The method of transport impacts pallet design significantly. Truck shipments experience lateral forces during turning and braking. Ocean containers expose pallets to high humidity, salt air, and extreme vibration. Rail transport introduces shock loads. Air freight demands the lightest possible pallet weight. We factor in your full transportation profile to prevent product damage and pallet failure in transit.
Environmental Exposure
Pallets used outdoors, in cold storage, or in high-humidity environments need special consideration. Cold storage pallets must resist moisture absorption and freeze-thaw cycles. Outdoor pallets need weather-resistant materials or treatments. Clean room pallets must meet particulate standards. We specify the right material, treatment, and coating for your operating environment.
Surface Treatments Available
Surface treatments improve appearance, hygiene, durability, and product compatibility. These are especially important for retail display, food handling, pharmaceutical, and export applications.
Planing (Smooth Finish)
Rough-sawn lumber is run through a planer to produce smooth, splinter-free surfaces. Reduces product damage from snags and splinters. Required for many food-grade and pharmaceutical applications. Planing also produces more consistent board thickness for tighter dimensional tolerances. Available on top deck, bottom deck, or all surfaces.
Sanding
Fine sanding produces an even smoother surface than planing, ideal for retail display pallets and environments where employees handle pallets without gloves. Sanded surfaces also accept paint and stain more evenly. We offer 80-grit (standard smooth), 120-grit (fine smooth), and 180-grit (ultra smooth) options.
Painting & Staining
Full pallet painting in any color for branding, color-coded inventory management, or aesthetic purposes. Industrial-grade paints resist chipping, moisture, and UV exposure. Staining provides a natural wood look with added weather protection. Common uses include retail displays, trade show pallets, and facility color-coding systems.
Sealing & Coating
Polyurethane sealers, epoxy coatings, and waterproof membranes protect pallets from moisture, chemicals, and biological contamination. Sealed pallets are easier to clean and sanitize, making them essential for food processing, pharmaceutical, and chemical handling environments. Anti-microbial coatings are available for hygiene-critical applications.
Anti-Slip Surfaces
Textured coatings, rubber grip strips, or applied grit surfaces prevent product sliding during transport. Anti-slip treatment is applied to the top deck surface and can be customized by zone — full coverage, center strip, or perimeter strips. Friction coefficient testing is available to verify performance against your specific product packaging.
Chamfering & Edge Profiling
Bottom lead boards are chamfered (angled) to create smooth entry points for forklift tines and pallet jacks. Reduces board damage during entry and prevents the pallet from catching on dock plates and conveyor transitions. Standard chamfer is 1.5 inches at 45 degrees. Custom chamfer angles and depths are available for specialized equipment.
Common Use Cases
Here are real-world examples of custom pallets we build regularly for businesses across Northeast Ohio and beyond.
Automotive Parts Manufacturer
Pharmaceutical Distribution Center
Craft Brewery
Steel Fabrication Shop
E-Commerce Fulfillment Center
International Chemical Exporter
Retail Display & Point of Sale
Cold Storage Warehouse
Order Quantities & Lead Times
Transparent pricing tiers and realistic timelines so you can plan your supply chain with confidence.
| Order Type | Minimum Qty | Typical Lead Time | Includes | Notes |
|---|---|---|---|---|
| Prototype / Sample | 1-5 units | 5-7 business days | Design, build, delivery | Prototype cost credited toward production order |
| Small Batch | 20-99 units | 7-10 business days | Design, build, QC, delivery | Ideal for testing or low-volume needs |
| Standard Order | 100-499 units | 5-10 business days | Design, build, QC, delivery | Volume pricing begins at this tier |
| Large Order | 500-2,000 units | 10-15 business days | Full engineering, QC, delivery | Dedicated production line allocation |
| High Volume | 2,000+ units | 15-20 business days | Full engineering, QC, staged delivery | Scheduled deliveries available weekly or biweekly |
| Rush Order | 20+ units | 3-5 business days | Expedited design, build, priority delivery | Rush surcharge applies (typically 15-25%) |
| Recurring Program | Flexible | Per agreed schedule | Warehousing, auto-reorder, dedicated inventory | Best per-unit pricing; ideal for ongoing needs |
No Minimum for Prototypes
We will build as few as one pallet to test your design. Prototype costs are credited toward your first production order of 100+ units. This removes the risk of committing to a large run before validating the design.
Staged Delivery Available
For large orders, we offer staged deliveries — receive pallets in weekly or biweekly shipments instead of all at once. This reduces your storage requirements and ensures a steady supply without warehouse overflow.
Recurring Order Programs
Set up a standing order for automatic replenishment. We maintain your pallet design on file, keep materials in stock, and ship on a regular schedule. Best per-unit pricing and zero lead time on reorders.
Sustainable Custom Options
Custom does not have to mean wasteful. We offer a full range of sustainable materials, processes, and programs to help you meet your environmental goals without compromising performance.
Recycled Wood Construction
Custom pallets built entirely from recycled and reclaimed lumber. We sort, inspect, and re-mill salvaged boards to meet your dimensional and structural requirements. Recycled wood pallets cost 20-40% less than new-lumber equivalents while performing identically for most applications. Every recycled pallet keeps wood out of landfills.
Recycled Plastic Pallets
Custom molded from 100% post-consumer recycled HDPE plastic — sourced from milk jugs, detergent bottles, and industrial plastic waste. These pallets are waterproof, chemical resistant, and last 10x longer than wood. At end of life, they are fully recyclable back into new pallets. Ideal for closed-loop supply chains.
Presswood / Composite Pallets
Made from compressed wood chips, sawdust, and binding agents — all byproducts of the lumber industry that would otherwise be waste. Presswood pallets are ISPM-15 exempt (no heat treatment needed for export), lightweight, and fully recyclable. They nest together for efficient storage and return shipping.
Design-for-Reuse Engineering
We engineer custom pallets specifically to maximize their reuse lifespan. This includes using bolted connections for easy field repair, hardwood in high-wear areas, replaceable deck boards, and standardized components. A pallet designed for reuse can survive 15-25 trips instead of the typical 5-8, dramatically reducing your per-trip pallet cost.
Take-Back & Recycling Program
We offer a full take-back program for custom pallets we build. When pallets reach end of life, we collect them, disassemble usable components for new builds, and recycle the remainder into mulch, animal bedding, or biomass fuel. Nothing reaches a landfill. Program available for orders of 100+ units within our service area.
Carbon Footprint Documentation
For companies tracking Scope 3 emissions or reporting to sustainability frameworks, we provide documentation of the carbon footprint of your custom pallet order. This includes material sourcing, manufacturing energy, transportation, and end-of-life recycling credits. Helps support ESG reporting and green supply chain certifications.
Our Environmental Certifications
Frequently Asked Questions
Answers to the most common questions we receive about custom pallet projects.
Ready to Build Your Custom Pallet?
Whether you have detailed specs or just a general idea, our team is ready to help. Describe your application and we'll design, prototype, and manufacture the perfect pallet for your needs. Most quotes returned within 24 hours.