Plastic Pallets

Superior Hygiene

The non-porous, closed-cell surface of plastic pallets resists bacteria, mold, fungal growth, and pest infiltration far more effectively than any wood pallet ever could. Unlike wood, which absorbs moisture and provides a breeding ground for microorganisms, plastic can be pressure-washed, steam-cleaned, or chemically sanitized and returned to service within minutes. This makes plastic pallets the only viable option for FDA-regulated food processing environments, pharmaceutical manufacturing, and medical device distribution where contamination could result in costly recalls or serious health consequences. Many plastic pallets are manufactured with antimicrobial additives that further inhibit bacterial colonization on the surface.

Lightweight Construction

Plastic pallets weigh up to 30-35% less than their wood counterparts of equivalent dimensions and load capacity. A standard 48x40 plastic pallet weighs between 15 and 50 pounds depending on design, compared to 40-75 pounds for a typical wood GMA pallet. This weight reduction translates directly into lower shipping costs per truckload, reduced fuel consumption across your entire logistics network, less physical strain on warehouse workers who handle pallets manually, and lower risk of workplace injuries. Over the course of thousands of shipments per year, the cumulative freight savings from reduced tare weight can be substantial enough to offset the higher upfront cost of plastic.

Exceptional Durability

Plastic pallets contain no nails, screws, staples, or fasteners that can loosen, protrude, or fail. There are no boards to crack, split, or break under impact. High-quality injection-molded plastic pallets routinely last 10 or more years in demanding closed-loop supply chains, completing 200+ trips without structural degradation. They are highly resistant to moisture, chemicals, UV exposure, and temperature extremes. Unlike wood, plastic does not warp, rot, swell, or delaminate when exposed to rain, humidity, or cold-storage conditions. The consistent structural integrity means fewer damaged loads, fewer product claims, and far fewer pallet replacements over time.

Export Ready (ISPM-15 Exempt)

One of the most significant advantages of plastic pallets for international shipping is their complete exemption from ISPM-15 (International Standards for Phytosanitary Measures No. 15). Because plastic pallets contain no wood fiber, they cannot harbor invasive insects or plant diseases and therefore require absolutely no heat treatment, fumigation with methyl bromide, or phytosanitary certification stamps. This eliminates costly treatment steps, reduces lead times for export shipments, avoids the risk of shipments being rejected at foreign ports for non-compliance, and simplifies customs documentation. For companies shipping to the EU, Australia, China, or any country with strict import biosecurity rules, plastic pallets eliminate an entire category of logistics headaches.

Dimensional Consistency

Every plastic pallet produced from a given mold is identical in dimensions, weight, and structural characteristics. There is zero variation between units, unlike wood pallets where moisture content, grain direction, knot placement, and lumber grade create significant unit-to-unit variability. This manufacturing precision makes plastic pallets ideal for automated material handling systems including AS/RS (Automated Storage and Retrieval Systems), robotic palletizers, conveyor systems, and automated guided vehicles (AGVs). Automated equipment that depends on consistent pallet dimensions for reliable operation experiences fewer jams, misfeeds, and downtime events when running plastic pallets compared to wood.

100% Recyclable

At end of life, plastic pallets are fully recyclable. The HDPE or PP material is ground into regrind flake or pellets and reprocessed into new pallets, plastic lumber, drainage pipe, automotive components, or dozens of other useful products. Many manufacturers operate take-back programs that pay a residual value for used plastic pallets, creating a circular economy that keeps material out of landfills. Even damaged or broken plastic pallets retain recycling value. Some companies report recovering 15-25% of their original pallet investment through end-of-life recycling credits. This cradle-to-cradle lifecycle makes plastic pallets one of the most sustainable packaging platforms in the supply chain.

No Splinters or Nails

Worker safety is a critical concern in any warehouse or distribution center. Wood pallets are one of the leading sources of workplace injuries, causing splinters, puncture wounds from protruding nails, lacerations from broken boards, and foot injuries from failed deck boards. Plastic pallets eliminate all of these hazards entirely. Their smooth, rounded edges and solid construction mean workers can handle them without gloves and without fear of injury. Facilities that switch from wood to plastic pallets frequently report significant reductions in their OSHA recordable incident rates and workers compensation claims, leading to lower insurance premiums and improved employee morale.

Chemical Resistance

Plastic pallets made from HDPE and PP are inherently resistant to a wide spectrum of chemicals including acids, alkalis, solvents, detergents, oils, and most industrial cleaning agents. They will not absorb chemical spills or retain odors from previous loads. This chemical inertness makes them essential for pharmaceutical distribution, chemical manufacturing, agricultural chemical storage, and any environment where pallets may come into contact with corrosive or reactive substances. Wood pallets exposed to chemical spills become contaminated, can leach chemicals into subsequent loads, and often must be disposed of as hazardous waste. Plastic pallets simply need to be wiped down or pressure-washed and put back into service.

Moisture Proof

Unlike wood, which absorbs water and can increase in weight by 20-30% in humid or wet conditions, plastic pallets have virtually zero moisture absorption. They maintain their original weight, dimensions, and structural properties whether they are stored in a climate-controlled warehouse, an outdoor yard in the rain, a blast freezer at -20 degrees Fahrenheit, or a tropical port during monsoon season. This moisture immunity prevents mold growth, eliminates the musty odors that contaminated wood pallets can transfer to products, and ensures consistent tare weights for freight billing purposes. Cold storage and frozen food operations particularly benefit from the moisture-proof nature of plastic pallets.

Easy Identification & Tracking

Plastic pallets can be molded with permanent color coding, embossed logos, serial numbers, and integrated RFID tag cavities that make them vastly easier to track and manage than generic wood pallets. Color-coded pallets help visually differentiate product lines, customers, or quality zones in a warehouse. Embedded RFID chips enable real-time automated tracking of pallet location, trip count, and cycle history without any manual scanning. Bar code labels adhere better and last longer on smooth plastic surfaces compared to rough wood. These identification capabilities support sophisticated pallet pooling programs and provide supply chain visibility that is simply impossible with unmarked wood pallets.

Consistent Tare Weight

Because plastic pallets do not absorb moisture, their tare weight remains constant regardless of environmental conditions. A plastic pallet that weighs 48 pounds in July will weigh 48 pounds in January. This consistency is extremely important for industries that sell products by weight, such as food, chemicals, and aggregates, where variable pallet weight can cause billing discrepancies, shipping overcharges, or regulatory non-compliance. Some food processors have reported paying thousands of dollars per year in phantom freight charges caused by wet wood pallets that weighed significantly more than their documented tare weight. Switching to plastic eliminated these discrepancies entirely.

Reduced Product Damage

The smooth, splinter-free surface of plastic pallets dramatically reduces the risk of damage to packaged goods. There are no rough edges to snag stretch wrap, no nail heads to puncture boxes, and no loose boards to shift and crush products during transit. Industries that ship high-value goods such as electronics, cosmetics, wine, and precision equipment report significantly lower damage claim rates after switching to plastic pallets. The consistent flat surface also provides a more stable base for stacking, which reduces load shifting and toppling during transportation. Some companies have calculated that the reduction in product damage claims alone justified the switch from wood to plastic within the first year.

High-Density Polyethylene (HDPE)

The most commonly used resin for plastic pallets. HDPE delivers an excellent balance of impact strength, chemical resistance, and low-temperature performance. It remains flexible and impact-resistant even in freezer environments as cold as -40 degrees Fahrenheit, making it the default choice for cold chain logistics, frozen food distribution, and outdoor storage applications. HDPE pallets resist acids, bases, solvents, and most industrial chemicals. They are FDA-compliant when manufactured from virgin resin and are widely recyclable through standard plastic recycling streams.

Polypropylene (PP)

Polypropylene offers higher stiffness and better heat resistance than HDPE, with a usable temperature range extending up to approximately 220 degrees Fahrenheit. This makes PP the preferred material for pallets used in hot-fill food processing, autoclaving operations, and environments where pallets pass through heat tunnels or high-temperature sanitization cycles. PP is lighter than HDPE at equivalent wall thickness, which can further reduce freight costs. However, PP becomes more brittle at low temperatures, so it is not recommended for deep-freeze storage applications below 32 degrees Fahrenheit without impact modification additives.

Recycled / Post-Consumer Plastic

Pallets made from recycled HDPE, recycled PP, or commingled post-consumer plastic waste offer the lowest cost per unit and the strongest environmental sustainability story. Recycled-content pallets divert thousands of tons of plastic waste from landfills each year and require significantly less energy to produce than virgin-resin pallets. They perform well for standard warehousing, export shipping, and general distribution applications. While their mechanical properties are slightly less consistent than virgin-resin pallets due to variations in the recycled feedstock, they are fully adequate for the vast majority of supply chain applications and often come at 20-40% lower cost than virgin alternatives.

Food safety regulations (FSMA, HACCP, SQF) increasingly require pallets that can be sanitized to microbial standards. Plastic pallets meet FDA 21 CFR food-contact requirements, resist bacterial harboring, and eliminate the risk of wood splinters contaminating food products. Dairy processors, meat packers, frozen food manufacturers, and beverage companies are among the heaviest adopters of plastic pallets. The ability to wash pallets to a validated sanitary standard between loads is critical in preventing cross-contamination and passing third-party food safety audits.

cGMP (Current Good Manufacturing Practice) regulations demand that materials entering pharmaceutical production areas be cleanable, non-shedding, and traceable. Plastic pallets fulfill all of these requirements. They do not generate particulates like wood, can be sanitized or autoclaved, and can carry individual serial numbers for full lot traceability. Medical device manufacturers, drug ingredient suppliers, and finished pharmaceutical distributors rely on hygienic plastic pallets to maintain validated cleanroom conditions and comply with FDA 21 CFR Parts 210/211.

Companies that ship to countries with strict phytosanitary import regulations benefit enormously from ISPM-15 exemption. Plastic pallets avoid heat treatment costs ($2-5 per pallet), fumigation delays, paperwork for phytosanitary certificates, and the risk of shipment refusal at destination ports. For high-volume exporters shipping hundreds or thousands of pallets per month, the elimination of these costs and delays represents a significant competitive advantage. Automotive parts exporters, electronics manufacturers, and agricultural exporters to the EU, Australia, and Asia-Pacific markets are heavy users.

Chemical manufacturers and distributors need pallets that resist corrosive acids, caustic bases, solvents, and petroleum products without absorbing or retaining hazardous materials. Plastic pallets made from HDPE or PP are chemically inert to the vast majority of industrial chemicals. When combined with spill containment features, they help facilities comply with EPA secondary containment regulations (40 CFR 264.175). Unlike contaminated wood pallets, which must be disposed of as hazardous waste, plastic pallets can typically be decontaminated and returned to service.

Frozen food distributors, ice cream manufacturers, and cold storage warehouses operate at temperatures from 32F down to -20F or colder. HDPE plastic pallets maintain their impact resistance and structural integrity at these temperatures, while wood pallets become prone to cracking and breakage as absorbed moisture freezes and expands within the wood fibers. Plastic pallets also eliminate the weight variability caused by ice accumulation on wet wood pallets in freezer environments, which can throw off inventory weights and freight billing.

Automotive assembly plants and Tier 1 suppliers operate highly automated material handling systems with conveyors, AGVs, and AS/RS that require dimensionally consistent pallets. The uniform size, weight, and structural characteristics of injection-molded plastic pallets dramatically reduce equipment jams and downtime compared to variable wood pallets. Additionally, automotive cleanroom paint shops require non-shedding, non-particulating pallets. Many automotive OEMs mandate plastic pallets for inbound parts delivery as a condition of their supplier quality standards.

Electronics manufacturers and distributors of high-value consumer products benefit from the clean, splinter-free surface of plastic pallets, which reduces the risk of packaging damage and product contamination. Some plastic pallets are available with static-dissipative or conductive properties to prevent electrostatic discharge (ESD) damage to sensitive electronic components. The smooth surface also provides better contact with stretch wrap, improving load stability for fragile items during transit. Reduced damage claim rates often justify the premium cost of plastic within the first year.

Large retail chains and e-commerce fulfillment centers process thousands of pallets daily through high-speed sortation and conveyor systems. Consistent pallet dimensions minimize conveyor jams and improve throughput. Display-style plastic pallets allow product to be merchandised directly on the pallet on the retail floor, eliminating rehandling labor. For e-commerce facilities, the lighter weight of plastic pallets reduces the physical demands on workers who may handle hundreds of pallets per shift, supporting ergonomic safety goals and reducing injury rates.

Static Load

The maximum weight a pallet can support when sitting stationary on a flat, solid surface such as a warehouse floor. Static load is the highest rated capacity because the full bottom surface is supported. Heavy-duty injection-molded pallets with reinforced ribbing can support up to 30,000 lbs static. Even lightweight nestable pallets typically handle 5,000-8,000 lbs in static conditions.

Dynamic Load

The maximum weight a pallet can safely carry while being moved by a forklift or pallet jack. Dynamic load is lower than static because the pallet must resist bending forces while being lifted from underneath by two fork tines. The dynamic rating assumes the load is evenly distributed across the deck surface. Concentrated point loads or off-center loading will reduce the effective dynamic capacity.

Racking Load

The maximum weight a pallet can support when placed on pallet racking where only the outer edges (typically 2-4 inches on each side) rest on the rack beams, leaving the center span unsupported. This is the most structurally demanding load condition. Only pallets specifically designated as rackable should be used on racking systems. Using non-rackable pallets on racking risks catastrophic failure.

Closed-Loop Recyclability

At end of life, plastic pallets are ground into regrind flake, washed, and reprocessed into new pallets or other durable plastic products. Unlike many consumer plastics that degrade in quality with each recycling cycle, the HDPE and PP used in pallets maintains sufficient mechanical properties for multiple recycling loops. Some plastic pallet manufacturers operate closed-loop take-back programs where they collect worn-out pallets, grind them, and remold the material into new pallets -- a true cradle-to-cradle cycle that keeps material in productive use and out of landfills indefinitely.

Carbon Footprint Reduction

A lifecycle analysis (LCA) comparing plastic pallets to wood pallets over multiple trip cycles consistently shows that reusable plastic pallets produce lower cumulative CO2 emissions per trip than single-use or short-life wood pallets. The lighter weight of plastic pallets also reduces fuel consumption during transportation. A fleet of 10,000 plastic pallets weighing 30 lbs less than their wood counterparts saves approximately 300,000 lbs of deadweight per full rotation, which translates to measurably lower diesel consumption and greenhouse gas emissions across the logistics network.

Landfill Waste Reduction

An estimated 500 million wood pallets end up in landfills in the United States every year, accounting for a significant portion of commercial solid waste. Plastic pallets that remain in closed-loop systems for 10+ years displace dozens of single-use wood pallets over their lifetime. When they do reach end of life, the plastic material retains economic value as recyclable feedstock, creating a financial incentive to recycle rather than discard. Responsible pallet users can achieve near-zero pallet waste by combining long-life plastic pallets with end-of-life recycling programs.

No Deforestation Impact

The wood pallet industry consumes approximately 40% of all hardwood lumber produced in the United States. While much of this comes from managed forests, the sheer volume of demand puts continuous pressure on forest resources. Plastic pallets made from recycled content require zero virgin timber and help reduce overall demand for pallet-grade lumber. For organizations with corporate sustainability commitments or ESG (Environmental, Social, and Governance) reporting requirements, switching to plastic pallets from recycled materials is a tangible, measurable step toward reducing reliance on forest resources.

Reduced Chemical Treatment

Wood pallets used in international shipping must be treated with heat or chemicals (historically methyl bromide, now largely phased out) to comply with ISPM-15. These treatments consume energy and, in the case of chemical fumigation, release harmful substances into the atmosphere. Plastic pallets require no treatment whatsoever, eliminating this entire category of environmental impact. For companies shipping internationally at volume, this adds up to a meaningful reduction in their overall environmental footprint.

Water Conservation

Cleaning and sanitizing plastic pallets in food and pharmaceutical applications uses significantly less water than attempting to clean wood pallets, because the non-porous surface does not absorb water and releases contaminants more readily during washing. Facilities report using 30-50% less water per pallet sanitization cycle when switching from wood to plastic. Additionally, plastic pallets dry almost instantly after washing, while wood pallets require extended drying times that consume energy and floor space. Some plastic pallet wash systems recirculate and filter wash water, further reducing consumption.

Plastic Pallet Economics

• Purchase Price$40-120 per pallet (injection molded)
• Expected Lifespan10+ years / 200+ trips
• Cost Per Trip$0.50-1.50
• Annual Repair Cost$0 (not repairable, but rarely fails)
• Replacement Rate2-5% of fleet per year
• Freight Savings15-35% weight reduction per load
• Product Damage Reduction30-60% fewer damage claims
• ISPM-15 Treatment Cost$0 (exempt)
• Sanitation CostLow (quick pressure wash)
• End-of-Life Value$3-8 recycling credit per pallet

Wood Pallet Economics

• Purchase Price$8-25 per pallet (new GMA)
• Expected Lifespan3-5 years / 15-20 trips
• Cost Per Trip$0.75-3.00
• Annual Repair Cost$2-5 per pallet per year
• Replacement Rate20-40% of fleet per year
• Freight SavingsBaseline (heavier tare weight)
• Product Damage RateBaseline (splinters, nails, debris)
• ISPM-15 Treatment Cost$2-5 per pallet per treatment cycle
• Sanitation CostHigh (cannot be effectively sanitized)
• End-of-Life Value$0.50-2.00 (mulch/recycling)

Temperature Performance

Chemical Compatibility Guide