What Is A Pallet? Uses, Types, Materials, & Sizes

Pallets play a crucial role in the efficient transportation and storage of heavy loads, ensuring that goods remain secure during shipping and handling. Selecting the right one is essential for optimizing loading and unloading processes and maximizing safety in warehouses and distribution centers. Learning about different types of pallets and their applications can help businesses make informed decisions that enhance shipping and storage processes. Don't underestimate the impact of choosing the ideal pallet — it's a key factor in streamlining operations and ensuring the safe delivery of products.

A pallet is a sturdy platform designed to provide efficient transportation and storage of large loads and heavy items. 

What are pallets used for? Pallets provide a stable base to keep goods secure during storage or shipping. They are moved using forklifts or pallet jacks. Products need to be on a pallet to be lifted by a forklift. Otherwise, uneven pressure distribution can occur and boxes could fall through the forklift’s forks, potentially leading to product damage and costly spills. The design of a pallet allows for uniform stacking and distribution of loads, making them essential for optimizing space, ensuring safety, and reducing the time and costs of manual handling. 

Pallets differ in design, material, size, load capacity, number of entry points, and price. Common materials include wood or plastic. 

The most popular dimensions are 48” x 40,” which are available in wood and plastic. Businesses can choose the most appropriate pallet type by considering factors such as the kind of goods being transported and frequency of use.

Wood pallets are widely used due to their affordability and ease of repair. They are also stackable and reusable.

These vary in types of wood including recycled wood, new wood, and heat-treated wood (sterilized). They are available with two-way and four-way access and range in load-bearing capacity from 1,000 to 5,000 lbs. Our wooden pallets come in sizes from 24” x 24” to 48” x 48.”

While plastic pallets are more expensive, they offer advantages such as durability and moisture resistance, making them suitable for industries with strict hygiene requirements. They have four-way access and range in sizes from 48” x 32” to 48” x 45.” They have the ability to carry heavier loads, with load capacities from 3,500 up to 17,600 lbs.

Different plastic options include:

• Industrial plastic: Industrial plastic pallets are designed for medium-duty industrial loads. They feature a nestable design that minimizes the required floor space and provide 4-way access. These pallets are resistant to acids, fats, solvents, and odors.
• Economy plastic: Cost-efficient economy plastic pallets are frequently utilized for standard air cargo, export, and one-way shipping. The pallets are resistant to insects, bacteria, and fungi, eliminating concerns about containment treatments.
• Heavy-duty plastic: Reusable heavy-duty plastic pallets feature a cruciform perimeter base that enables heavy-duty block stacking. They also provide 4-way access, making them compatible with forklifts and pallet jacks.
• Rackable plastic: Rackable plastic pallets are recognized for their excellent stacking support capabilities. They feature locking rings that facilitate the stacking of empty pallets. These pallets are designed without spaces that could harbor liquids or debris.

Pallets vary in size depending on what they will be used to support and ship. The most common is the American Pallet, also often referred to as the North American or GMA (Grocery Manufacturers Association) Pallet.

The American Pallet gets its name from the standard pallet size used in American logistics: 48” x 40. It is larger and sturdier than most European pallets. It is available with four-way access in both wood and plastic materials with a load capacity of up to 17,600 lbs. They come in plastic economy, industrial plastic, heavy-duty plastic, heat-treated wood, and recycled wood.

Sizes vary to ensure there’s a compatible fit for every application. Other dimensions include 30” x 30,” 47” x 32,” 48” x 36,” 48” x 45,” and more.

Two-way and four-way access pallets are the most common types used in logistics and warehousing. The number of access points is the amount of sides the pallet can be lifted at with a forklift or jack. Two-way access means that the pallet can be lifted, or accessed, from two different sides. Four-way access provides users with the ability to lift the pallet from any of its four sides. 

Wood and plastic are the most widely used materials for pallets in warehouses. The type of material that it is made of is important to keep in mind when deciding what to select for your industry and application as strength, shipping weight, compatibility, and more vary.

Wood pallets are either made from softwoods such as pine and fir for lightweight and cost-effectiveness or hardwoods such as oak and maple for increased strength and durability. They weigh anywhere from 14 to 36 lbs. based on size and construction. 

They are also eco-friendly, as they can be recycled. With proper care and repairs, they can last 3 to 5 years in regular use. They are more difficult to clean due to their porous surface and they tend to absorb liquids. These are mainly used in manufacturing, agriculture, retail, and construction.

Typically, plastic pallets are made of high-density polyethylene (HDPE) or polypropylene (PP), making them more resistant to chemicals, liquids, cracking, and splintering. They usually weigh between 20 to 33 lbs. Plastic is easier to clean and doesn’t attract pests as wood can. While plastic options cost more than wooden, they can last up to 10 years or more based on care and frequency of use.

Some pallets are made of cardboard or metal for specific applications. Cardboard pallets, made from corrugated cardboard, are lightweight and mostly used for some food and pharmaceutical air freight. They are more of a one-time or limited-time use. 

Metal pallets are used for extremely heavy loads and items, made of strong steel or aluminum. They’re used within the automotive, aerospace, and manufacturing industries. While they can be reused many times, they are heavier and more expensive than plastic or wood.

There are industries and applications in which a specific type of pallet is required. Reversible, closed, and wing pallets all have unique benefits to their construction and design.

Reversible pallets feature identical top and bottom decks, which allows them to be able to be used on either side. This is ideal for when it needs to be flipped or uniformly stacked. Having a double deck created a sturdier surface.

Also known as a solid deck, closed pallets have a flat top surface with no gaps. They are mainly made from plastic or metal, making the top surface easy to clean.

Wing pallets have extended boards that extend beyond the sideboards, creating “wings” on the sides of the board. They’re most used for large or irregularly shaped items. This provides extra space for wrapping goods to ensure they remain secure during transport.

Selecting the ideal pallet depends on the items, load capacity, size, and material, as well as the product and industry. We understand how important it is to have a reliable pallet to ship and transport goods. That’s why we offer a wide variety of wood and plastic pallets.

Have any questions or need assistance in choosing which would be best? Contact our product specialists at 630.629.6600 or email sales@thecarycompany.com.