Warehouse & Distribution
High-performance pallet solutions for the backbone of the supply chain
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Warehouse Pallet Management Best Practices
Implement these practices to reduce pallet-related costs, prevent damage, and keep your warehouse running efficiently.
Inspect Pallets Before Racking
Check every pallet before placing it in racking for broken boards, cracked stringers, protruding nails, and excessive warping. A single failed pallet in racking can cause a catastrophic collapse affecting multiple positions. Our Grade A pallets are pre-inspected, but a quick visual check at point-of-use is always recommended.
Match Pallets to Racking Type
Different racking systems require different pallet specifications. Drive-in racking needs precise runner alignment, push-back requires Grade A consistency, and AS/RS demands block pallets with tight tolerances. Using the wrong pallet in the wrong racking is a safety hazard and a productivity killer.
Set Stacking Limits
Never stack pallets higher than your equipment can safely reach or your pallets can safely support. General rule: stack no more than 5 empty pallets high, and limit loaded pallet stacking based on product and pallet capacity. Mark stacking limits clearly with signage in your warehouse.
Sort and Grade Incoming Pallets
When pallets arrive at your receiving dock (from suppliers, not from us), sort them immediately into reusable, repairable, and recyclable categories. Reusable pallets go back into circulation, repairable ones get staged for repair, and recyclable ones get staged for our pickup service.
Rotate Pallet Stock (FIFO)
Use oldest pallets first to prevent degradation from extended storage. Wood pallets absorb moisture over time, especially if stored outdoors. Rotate your pallet inventory the same way you rotate your product inventory — first in, first out.
Store Pallets Properly
Store empty pallets on a flat, dry surface away from standing water. Indoor storage is ideal. If storing outdoors, elevate stacks on a gravel or concrete pad and cover with tarps. Wet pallets lose 10-20% of their load capacity and gain 15-25% in weight.
Train Your Team on Pallet Safety
Ensure all forklift operators and warehouse workers understand proper pallet inspection, handling, and stacking procedures. Common injuries from pallet incidents include foot injuries from dropped pallets, hand injuries from splinters and nails, and crush injuries from stack collapses.
Implement a Buyback Program
Instead of paying for pallet disposal, partner with us for a buyback program that converts waste into revenue. We pay $2-5 per pallet for reusable units and provide free recycling for damaged ones. The average warehouse saves $800-2,000/month by switching from disposal to buyback.
Use Pallet Collars for Containment
Pallet collars transform flat pallets into stackable containers without the cost of custom crating. They are reusable, foldable for return shipping, and create instant containment for parts, produce, and small items. A much more efficient alternative to shrink-wrap and cardboard for many applications.
Problems We Solve for Warehouses
Warehouse managers face daily pallet headaches. Here is how we eliminate every one of them.
Challenge: Inconsistent pallet quality slows operations
Every pallet is individually inspected and graded against documented standards. You get consistent, reliable quality every time so your forklifts, conveyors, and racking systems run without interruption. Our rejection rate on delivered pallets is less than 0.5%.
Challenge: Used pallets piling up at your dock
Our scheduled pickup service removes surplus pallets on a weekly or bi-weekly basis. We pay you for reusable pallets and recycle the rest — no landfill, no hassle. Most customers turn a disposal expense into revenue of $2-5 per pallet.
Challenge: Emergency orders disrupt your supply chain
We maintain 10,000+ pallets in local inventory. Same-day and next-day fulfillment available for standard sizes so you never run short during peak periods. Our Gold partners get same-day emergency fulfillment at no surcharge, 365 days a year.
Challenge: Pallet damage increases product loss
Our rigorous inspection process eliminates structurally compromised pallets. We check nail protrusion, board integrity, stringer cracks, load-bearing capacity, and dimensional accuracy on every single unit before delivery.
Challenge: Non-standard pallets cause racking failures
We match pallet dimensions exactly to your racking beam span. Oversized pallets overhang beams and create unsafe conditions. Undersized pallets do not seat properly. We measure your racking and supply pallets that fit perfectly.
Challenge: Automated systems jam on inconsistent pallets
For warehouses with robotic palletizers, AS/RS, or conveyor systems, we offer precision-graded pallets with +/- 1/4 inch tolerances. Block pallets with consistent weight and dimensions eliminate automation jams and line stoppages.
Challenge: Multiple pallet vendors create management headaches
Consolidate your pallet supply to one trusted partner. We handle new pallets, used pallets, custom sizes, heat treatment, accessories, buyback, and recycling — all from one vendor with one account representative and one invoice.
Challenge: No visibility into pallet costs and consumption
Our partner portal provides detailed reporting on your pallet orders, deliveries, buyback volumes, and total spend. Monthly and quarterly reports help you track consumption patterns, identify savings opportunities, and budget accurately.
Challenge: Seasonal demand spikes cause pallet shortages
For seasonal businesses, we pre-position inventory based on your historical patterns. You never scramble for pallets during peak season because we have already allocated your supply weeks in advance.
Challenge: Disposal costs eat into your operating budget
Our buyback and recycling programs eliminate disposal costs entirely. Instead of paying a waste hauler $1-3 per pallet, you receive $2-5 per pallet from us. That transforms a cost center into a revenue stream.
Our Warehouse Solutions
Comprehensive programs designed specifically for distribution operations of all sizes
High-Volume Supply Programs
Guaranteed pallet availability with standing orders and reserved inventory. Whether you need 500 or 5,000 pallets per week, we maintain a dedicated supply buffer tailored to your consumption rate. Automatic restock triggers ensure you never run short.
Pallet Buyback & Recycling
Turn your pile of used pallets into revenue. We purchase quality used pallets at competitive per-unit rates and provide free recycling for damaged units. Reduce waste disposal costs to zero while generating income from what was previously a waste stream.
On-Site Pallet Management
For high-volume operations (2,000+ pallets/month), we embed our team at your facility to sort, grade, and manage pallets on-site. This eliminates double-handling, maximizes pallet reuse within your operation, and provides real-time inventory visibility.
Custom Sizing Programs
If your warehouse uses non-standard racking or serves clients with unique size requirements, we build and maintain custom-size pallet inventories specific to your operation. Consistent quality and availability, regardless of size.
Racking Compatibility Assessment
Our team measures your racking beam spans, clearances, and load ratings to recommend the exact pallet specifications that ensure safe, efficient storage. Incompatible pallets cause racking failures, product damage, and safety hazards.
Pallet Exchange Programs
We deliver fresh pallets and pick up your used ones in the same trip. This eliminates storage of used pallets at your facility, provides a consistent supply, and generates buyback revenue — all in a single, efficient logistics operation.
Racking Compatibility Guide
Using the wrong pallet in the wrong racking system is dangerous and costly. Here is our complete guide to matching pallets with racking types.
Selective Pallet Racking
The most common warehouse racking system. Single-deep racking with direct fork access to every pallet position.
Pallet width must match beam span exactly (+/- 1/2 inch). Standard 48x40 GMA pallets fit 8-foot beams with 2-inch overhang per side. Grade A or B recommended. Bottom deck boards must be in excellent condition for beam support.
Drive-In / Drive-Through Racking
Deep storage racking where forklifts drive into the structure. Pallets sit on rails, not beams.
Pallet bottom runners (stringers) must align perfectly with rack rails. 2-way entry pallets required for drive-in. Block pallets not recommended unless rails are modified. Consistent pallet height is critical.
Push-Back Racking
Pallets are loaded from the front and pushed back on wheeled carts. LIFO (last in, first out) storage method.
Extremely consistent dimensions required. Pallets must fit cart cradles exactly. Weight must be within cart rating. Grade A pallets strongly recommended. Bottom deck must be smooth (no protruding nails).
Pallet Flow / Gravity Racking
Pallets are loaded at the back and roll forward on gravity rollers. FIFO (first in, first out) method.
Pallets must have smooth, consistent bottom surfaces for roller compatibility. Block pallets with full bottom decks work best. Stringer pallets may catch on rollers. Weight must be within roller capacity.
Cantilever Racking
Open-front racking for long, bulky items (lumber, pipes, carpet rolls). No front uprights.
Standard pallets often not used with cantilever. When needed, use oversized pallets that span multiple arm levels. Custom long pallets (60-72 inch) may be required for proper load distribution.
AS/RS (Automated Storage & Retrieval)
Fully automated crane-operated racking system. Highest precision requirements.
Strictest tolerance requirements: +/- 1/4 inch on all dimensions. Block pallets with full 4-way entry required. Consistent weight within 5 lbs. No protruding nails, splinters, or warping. New or Grade A only.
Automated System Compatibility
Modern warehouses rely on automation. Here is how our pallets integrate with the most common automated warehouse systems.
| System | Pallet Requirements | Our Recommendation |
|---|---|---|
| Robotic Palletizers | +/- 1/4" dimensional tolerance, consistent height, flat top surface, no warping or protruding nails | New block pallets or precision-graded Grade A |
| Automated Guided Vehicles (AGVs) | Standard 48x40 footprint, consistent fork pocket dimensions, clean bottom deck, no loose boards | Grade A stringer or block pallets |
| Conveyor Systems | Consistent weight (+/- 5 lbs), no protruding fasteners, smooth bottom runners, standard dimensions | Grade A stringer pallets with inspected bottom deck |
| Stretch Wrappers | Standard dimensions, consistent height, no excessive deck board gaps, stable load platform | Any Grade A or B pallet |
| Pallet Dispensers | Exact dimensional consistency, standard height (5.5-6"), no warping, consistent stacking profile | New pallets or premium Grade A |
| Barcode/RFID Scanning | Consistent placement of pallet tags/labels, flat surface area for tag application, no interference with readers | Block pallets with designated tag area |
How a Wichita Distribution Center Saved $45,000/Year
Background: A mid-size distribution center in east Wichita was purchasing 1,200 new pallets per month at $12.50 each ($15,000/month) and paying a waste company $800/month to haul away 800 used pallets.
The Problem: Annual pallet spend was $180,000 for new pallets plus $9,600 for disposal — a total of $189,600/year. The warehouse manager knew there had to be a better way but had never explored recycled pallet options.
Our Solution: We implemented a combined supply and buyback program. We replaced their new pallet purchases with inspected Grade A used pallets at $5.00 each, and converted their disposal expense into buyback revenue at $3.00 per pallet for their reusable returns.
Implementation: We started with a 30-day trial on one dock. After the warehouse team confirmed Grade A quality met their standards (it exceeded expectations), we rolled the program across all six loading docks within 60 days.
Results: The distribution center now spends $60,000/year on Grade A pallets (down from $180,000 on new) and receives $28,800/year in buyback revenue (up from negative $9,600 in disposal costs). Net annual savings: $45,000+ while diverting 14,400 pallets from the landfill each year.
Results at a Glance
Recommended Products for Warehouses
Ready to Optimize Your Pallet Operations?
Let us design a custom supply and recycling program for your warehouse. Free consultation, facility assessment, and racking compatibility analysis included.