Recycling & Repair

Cracked, split, or missing deck boards are removed and replaced with matching lumber of the same species, thickness, and width. Our inventory includes pre-cut replacement boards in every standard dimension, allowing us to complete most board replacements in minutes. We match the grain direction and ensure the replacement board sits flush with adjacent boards to maintain a level deck surface for safe load support.

Stringers — the long support boards that run the length of a pallet — are the backbone of structural integrity. When a stringer cracks at or near the notch (the cut-out that allows forklift entry), we repair it using a companion stringer or metal repair plate. A companion stringer is a piece of lumber nailed alongside the damaged area, effectively splinting the break. This restores the pallet to full load-bearing capacity without replacing the entire stringer.

When stringer damage is too extensive for a notch repair — such as a full break, severe rot, or insect damage — we remove the entire stringer and replace it with a new one. This involves removing all fasteners connecting deck boards to the damaged stringer, sliding in a replacement stringer of the same dimension and species, and re-nailing every connection point. The result is a pallet with structural integrity identical to a new build.

Chamfering involves beveling the leading edges of the bottom deck boards on a pallet. This angled cut (typically 45 degrees) allows forklift tines and pallet jack wheels to slide under the pallet more easily, reducing the risk of catching, lifting, or damaging the leading boards. Chamfering is especially important for pallets used in automated warehouse systems where smooth entry is critical for conveyor and racking equipment.

Over time, nails work loose due to vibration, impact, and load cycling. Loose nails compromise the connection between deck boards and stringers, reducing the pallet load capacity and creating a safety hazard. Our re-nailing process involves pulling every loose, bent, or protruding nail and replacing it with a properly driven fastener. We use ring-shank or screw-shank nails that provide superior holding power compared to the smooth-shank nails often used in original construction.

Warped, oversized, or unevenly protruding boards are trimmed to proper specifications. This process ensures that the pallet meets dimensional tolerances required for automated warehouse systems, racking, and shipping containers. We use precision-guided saws to trim boards flush with the pallet edge, remove splinters and rough edges, and bring non-standard pallets into compliance with GMA or customer-specific dimensions.

Pallets that have been used in outdoor storage, agriculture, or food-adjacent environments may accumulate dirt, debris, organic matter, or surface contaminants. Our cleaning process involves power washing or air blasting to remove surface contamination, followed by inspection for stains that might indicate chemical exposure. Clean pallets are safer, easier to inspect, and acceptable for a wider range of applications including food distribution.

The lead boards — the outermost deck boards on each end of the pallet — take the most abuse during handling. They are the first point of contact with forklift tines, dock edges, and stacking surfaces. We see more damage to lead boards than any other component. Replacement involves removing the damaged lead board, selecting a matching replacement, and fastening it with ring-shank nails. For high-traffic pallets, we may recommend upgrading to a thicker or harder-species lead board for extended life.

Block pallets use small wooden blocks instead of continuous stringers. When blocks crack, crush, or split — typically from point loading or improper forklift handling — we remove the damaged block and install a new one. Block replacement restores the pallet four-way entry capability and load-bearing capacity. We stock replacement blocks in standard sizes for the most common block pallet designs.

Our highest-volume byproduct. Ground pallet wood is screened to a consistent particle size, colored with non-toxic dyes (natural, red, black, or brown), and sold to landscape supply companies, garden centers, municipal parks departments, and commercial property management firms. Mulch suppresses weeds, retains soil moisture, regulates soil temperature, and adds organic matter as it decomposes.

Clean, kiln-dried wood shavings and chips processed to specific particle sizes for use as livestock bedding in horse stalls, cattle barns, poultry houses, and small animal enclosures. Our bedding material is screened for splinters and metal fragments, tested for absorbency, and packaged in compressed bales for easy handling and storage.

Wood chips that do not meet the specifications for mulch or bedding are processed into biomass fuel for industrial boilers and co-generation plants. Pallet wood has a favorable energy content (approximately 8,000 BTU per pound for dry hardwood) and burns cleaner than coal. Our biomass chips are a renewable energy source that displaces fossil fuels.

Fine wood particles and sawdust from our grinding operations are mixed with nitrogen-rich green waste to create high-quality compost. The carbon-rich wood provides the structural matrix that aerobic decomposition bacteria need to thrive. The finished compost is used by farms, nurseries, and municipal composting programs.

Clean wood chips of consistent size are sold to engineered wood product manufacturers who press them with resins and adhesives to create particle board, MDF (medium-density fiberboard), and OSB (oriented strand board). These products are used in furniture, cabinetry, shelving, and construction.

Coarser wood chips and fiber mats are used for erosion control on construction sites, steep slopes, and waterway banks. The material slows water runoff, filters sediment, and provides a degradable ground cover that allows vegetation to establish. Municipalities and construction companies are regular buyers.