Custom Pallets
Engineered to your exact specifications — any size, any material, any treatment
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Your Product, Your Pallet
Not every product fits a standard pallet. We design and build custom pallets tailored to your specific dimensions, weight requirements, and shipping conditions. From initial consultation to final delivery, every custom pallet we produce is engineered for your exact application.
Custom Dimensions
Any length, width, and height. We build to your exact measurements, whether you need oversized pallets for industrial equipment or compact pallets for small goods. No size is too large or too small for our shop.
Material Options
Choose from hardwood, softwood, plywood, plastic, or composite materials. Each has unique advantages for different applications. We help you select the material that best balances performance, cost, and weight.
Load Engineering
We calculate board thickness, spacing, and stringer placement based on your specific load weight and distribution requirements. Every custom pallet is engineered to handle your load with a built-in safety margin.
Special Treatments
Heat treatment (ISPM-15), fumigation, moisture treatment, or anti-fungal coating. Meet any regulatory or environmental requirement with our range of treatment options and certified processes.
Branding & Marking
Add your company logo, handling instructions, or tracking codes directly on the pallet. Stencil, hot brand, or ink-stamp options available. Color coding and full-pallet painting also available.
Reusable Design
We can design your custom pallets for multiple trips, with reinforced construction and easy-repair features for maximum lifecycle. Reusable designs reduce your long-term pallet cost per use significantly.
Real-World Custom Pallet Examples
Here are examples of custom pallet solutions we have built for businesses across different industries. Each project presented unique challenges that standard pallets could not solve -- and our custom engineering delivered the answer.
Aircraft Engine Component Pallet
Aviation / AerospaceAnti-vibration rubber mounts, steel corner reinforcements, ISPM-15 certified, custom foam cradle inserts to prevent component movement during air transport.
Grain Silo Component Shipping Pallet
AgricultureExtended runner length for crane lifting, forklift pockets reinforced with steel plates, weather-treated for outdoor staging. Designed for oversized cylindrical components.
Medical Device Display Pallet
Healthcare / Trade ShowsFood-safe clear coat finish, company logo hot-branded on all four sides, integrated product mounting holes, lightweight design for trade show portability.
HVAC Unit Shipping Platform
ManufacturingFull four-way entry, double-deck top and bottom, custom bolt-down brackets for securing HVAC units, forklift guide rails on underside.
E-Commerce Fulfillment Mini Pallet
Retail / E-CommerceDesigned for small parcel automation systems, tight dimensional tolerance (1/8"), compatible with conveyor rollers, stackable when empty, disposable cost point.
Brewery Keg Pallet
Food & BeverageRaised edge rails to prevent keg rolloff, full deck with no gaps, drain channels for spill management, food-safe coating, stackable when loaded.
Solar Panel Transport Pallet
Renewable EnergyVertical A-frame design for edge-loading solar panels, foam padding on all contact surfaces, nylon strap attachment points, reusable across 50+ shipping cycles.
Automotive Parts Racking Pallet
AutomotiveEngineered specifically for automated racking systems, precise dimensions within 1/8", RFID tag pocket built into corner block, beveled edges for clean conveyor travel.
Cleanroom Equipment Pallet
Pharmaceutical / SemiconductorFully sealed surfaces to prevent particle shedding, low-VOC sealant coating, no exposed fasteners, shrink-wrapped before delivery to maintain cleanliness.
Wind Turbine Blade Support Pallet
Renewable EnergyCustom V-cradle for cylindrical blade roots, adjustable width supports, heavy-gauge steel skid rails for dragging, rated for crane lifting from four points.
Retail Promotion Display Pallet
Retail / MarketingQuarter-pallet size for end-cap displays, printed brand graphics on all visible surfaces, integrated product dividers, easy-assembly design that ships flat.
How Custom Orders Work
From initial concept to final delivery, our 8-step custom pallet process ensures you receive a product that is engineered, tested, and built to your exact requirements.
Consultation
We start with a detailed discussion of your requirements -- product dimensions, weight, shipping method, handling equipment, storage conditions, regulatory needs, and budget targets.
Site Assessment
For complex projects, we visit your facility to observe your actual handling processes, measure your products, and understand the real-world conditions your pallet must survive.
Engineering Design
Our design team creates a detailed pallet specification including dimensions, material selection, fastener patterns, load distribution calculations, and stacking configurations.
Material Sourcing
We source the specified lumber species, treatments, and specialty components. For unique requirements, we work with our supplier network to find the right materials at competitive prices.
Prototype Build
A small batch of prototypes (typically 3-5 units) is built for your review and testing. Prototypes let you verify fit, function, and compatibility before committing to full production.
Testing & Validation
Prototypes are load tested, fit tested with your actual products, and evaluated for forklift handling, stacking stability, and racking compatibility. Design adjustments are made as needed.
Production Run
Once the design is approved, we begin full production using calibrated jigs and fixtures to ensure every pallet matches the approved prototype. Quality checks run continuously through production.
Delivery & Support
Your custom pallets are delivered to your facility on your schedule. We follow up to confirm satisfaction and keep your specifications on file for easy reordering of future batches.
Choosing the Right Material for Your Custom Pallet
The material you choose impacts every aspect of your custom pallet -- from load capacity and weight to cost, durability, and regulatory compliance. Here is a comprehensive guide to help you make the best decision.
| Property | Hardwood | Softwood | Plywood | Plastic | Composite |
|---|---|---|---|---|---|
| Load Capacity | Highest | Moderate-High | Moderate | High | Varies |
| Weight | Heaviest | Moderate | Light | Light-Moderate | Lightest |
| Cost | Higher | Moderate | Moderate | Highest | Varies |
| Moisture Resistance | Moderate | Low | Low (unless treated) | Excellent | Good-Excellent |
| Pest Resistance | Needs treatment | Needs treatment | Needs treatment | Immune | Immune |
| ISPM-15 Compliance | Heat treatment | Heat treatment | Under 6mm exempt | Exempt | Exempt |
| Reuse Cycles | 15-20+ | 8-12 | 5-8 | 50-100+ | 10-30 |
| Recyclability | Repair & reuse | Repair & reuse | Limited | Melt & reform | Varies |
| Customizability | High | High | Moderate | Requires molds | Moderate |
| Best Application | Heavy-duty, racking | General purpose | Smooth deck needs | Clean environments | Export, air freight |
Engineering Considerations for Custom Pallets
A well-engineered custom pallet accounts for much more than just the weight of the product. Here are the critical engineering factors our design team evaluates for every custom project.
Load Distribution Analysis
- Uniform vs. concentrated load -- affects board spacing and thickness requirements
- Point load locations -- determines where reinforcement is needed
- Center of gravity height -- impacts stacking stability and tip-over risk
- Load overhang -- products extending beyond pallet edges require wing designs
- Dynamic load amplification during transport -- vibration, braking, and cornering add 20-40% to effective load
Stacking Considerations
- Maximum stack height in warehouse (typically 3-5 pallets high)
- Bottom pallet must support cumulative weight of all stacks above
- Product-to-pallet contact surface area determines compression stress
- Interlocking vs. column stacking patterns affect required pallet stiffness
- Floor load limits in your warehouse may restrict total stack weight
Racking Requirements
- Beam spacing determines unsupported span and required pallet stiffness
- Pallet must resist bending (deflection) under full load across the span
- Bottom deck boards must align with rack beam positions for stability
- Dimensional accuracy is critical -- tight tolerances prevent racking failures
- Block pallets generally outperform stringer pallets in racking applications
Handling Equipment Compatibility
- Fork pocket dimensions must match your forklift and pallet jack forks
- Entry type (2-way vs. 4-way) must match your warehouse traffic patterns
- Pallet weight when loaded must be within your forklift rated capacity
- Conveyor compatibility requires consistent dimensions and bottom deck profile
- Automated systems need tight tolerances (typically within 1/8" to 1/4")
Environmental Exposure
- Indoor-only pallets can use untreated wood for maximum cost savings
- Outdoor exposure requires moisture treatment, sealed ends, or plastic materials
- Freezer and cold storage applications require kiln-dried wood to prevent ice expansion damage
- High-humidity environments need anti-fungal treatment to prevent mold
- Chemical exposure environments may require plastic or sealed-wood construction
Transportation Mode
- Truck -- standard pallets work for most road transport applications
- Rail -- higher vibration requires reinforced joints and fastener patterns
- Ocean container -- moisture resistance and ISPM-15 compliance are essential
- Air freight -- weight is critical; lightweight composites or thin-gauge designs preferred
- Intermodal -- must survive multiple handling transfers; durability is paramount
Specialty Pallet Types We Build
Beyond standard custom dimensions, we build specialty pallets designed for specific industries and applications that require unique engineering solutions.
Display Pallets
Sanded, sealed, and finished pallets designed to be seen by customers. Used in retail stores, trade shows, and showrooms. Available with brand printing, color finishes, and integrated product displays.
- Sanded smooth all surfaces
- Clear coat or painted finish
- Brand logo integration
- Quarter, half, or full pallet sizes
Export Pallets
ISPM-15 certified pallets built for international shipping compliance. Available in all sizes and materials. Heat treated and stamped for customs clearance in 180+ countries.
- ISPM-15 heat treated
- IPPC stamp applied
- Lightweight options for air freight
- Container-optimized dimensions
Heavy-Duty Pallets
Engineered for loads exceeding 4,000 lbs. Uses hardwood construction, reinforced stringers, additional deck boards, and heavy-gauge fasteners. Designed for machinery, equipment, and industrial products.
- Load ratings to 10,000+ lbs
- Hardwood or steel-reinforced
- Extra stringer and board count
- Tested to exceed rated capacity
Cleanroom Pallets
Sealed, particle-free pallets for pharmaceutical, semiconductor, and food processing cleanrooms. Surfaces are fully sealed to prevent wood particle shedding. Delivered shrink-wrapped.
- Fully sealed surfaces
- Low-VOC coatings
- No exposed fasteners
- Cleanroom-packaged delivery
Nestable Pallets
Designed to nest inside each other when empty, reducing storage footprint by up to 60%. Popular for businesses with limited empty pallet storage space or high return-shipping costs.
- 60% storage savings when empty
- Lightweight design
- Tapered leg construction
- Ideal for return logistics
Racking-Optimized Pallets
Engineered specifically for pallet racking systems with precise dimensions, maximum bending resistance, and bottom deck boards positioned to align with standard rack beam widths.
- Precise dimensional tolerance
- Reinforced center span
- Bottom boards aligned to beams
- Compatible with AS/RS systems
Spill-Containment Pallets
Built with integrated containment lips, drain channels, or sealed deck surfaces to capture and contain liquid spills. Required for hazardous material storage and chemical warehouse applications.
- Raised edge containment
- Sealed or lined deck surface
- EPA/OSHA compliant designs
- Optional drain fittings
Stackable Crate Pallets
Pallets with integrated sides or collar attachment points that convert into stackable crates. Combines the pallet and container into a single reusable unit for efficient closed-loop logistics.
- Integrated side walls or collar mounts
- Stackable when loaded
- Collapsible for return shipment
- Reduces packaging waste
Prototype and Testing Process
We never go straight from design to full production on custom orders. Our prototyping process lets you test, verify, and refine the design before committing to a full production run. This eliminates costly mistakes and ensures the final product works perfectly in your real-world environment.
Prototyping is included in the cost of every custom order over 100 units. For smaller orders, prototyping is available at a nominal cost that is credited back to your production order. We believe testing before production is an investment that always pays for itself.
Phase 1: Design Review
Before any wood is cut, we review the complete design specification with you. This includes dimensional drawings, material specifications, load calculations, and a detailed cost estimate. Changes at this stage cost nothing.
Phase 2: Prototype Construction
We build 3-5 prototype pallets using the exact materials and construction methods specified in the design. Prototypes are built with the same care and quality as production units -- no shortcuts.
Phase 3: In-House Testing
Prototypes undergo static load testing, dynamic fork handling, and racking span testing (if applicable). We measure deflection, check for joint failures, and verify dimensional accuracy across all units.
Phase 4: Customer Testing
We deliver prototypes to your facility for real-world testing. You load them with your actual products, run them through your handling processes, and verify compatibility with your equipment and systems.
Phase 5: Design Refinement
Based on testing feedback, we make any necessary adjustments to the design. Common refinements include board spacing changes, stringer repositioning, fastener upgrades, or material substitutions.
Phase 6: Production Approval
Once you are fully satisfied with the refined prototype, you sign off on the final design. We lock the specification, build production jigs and fixtures, and begin your full order.
Ready to Build Your Custom Pallet?
Every custom project starts with a free consultation. Tell us about your product, your challenges, and your goals -- and we will design the perfect pallet solution. No obligation, no minimum order for quotes.
Start Your Custom Order