This article contains everything you need to know about Shipping Pallets.
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Shipping pallets serve as foundational platforms crafted to support various items, products, equipment, and materials, streamlining handling during transport and storage operations. Introduced alongside forklifts in the early 20th century, pallets replaced traditional storage solutions like kegs, boxes, and barrels. This revolutionary change significantly enhanced material storage, organization, and protection, establishing them as a vital element of warehousing. Today, approximately two billion pallets are in circulation globally.
The standard shipping pallet dimensions in North America, particularly in the United States, are 48 x 40 x 6 inches with a weight ranging from 30 lbs to 40 lbs. Despite pallets being available in an array of sizes and configurations, the standard size dominates due to its compatibility with warehouse racking systems. These pallets are manufactured from diverse materials such as wood, plastic, metal, paper, and recycled aluminum and paper. Among these, wood remains the most prevalently used material.
Shipping pallets are specifically engineered for efficient handling by forklifts or pallet jacks, facilitating processes such as stacking, transporting, and storing goods. Various industries have tailored pallet designs to enhance product protection and simplify logistics. Depending on the nature of the goods in transit, additional security measures like plastic film wrapping or strapping are often employed.
Plastic pallets offer numerous advantages, including superior durability, strength, cost efficiency, and resistance to microbial contamination and chemicals. Consequently, they are increasingly favored as the material of choice for pallets.
Given the essential role of shipping pallets in logistics and supply chain management, organizations establish standards for pallet dimensions and sanitation protocols. These guidelines are designed to minimize transport delays and potential challenges while safeguarding the health of workers, end-users, and preserving the biodiversity of destination regions.
Shipping pallets are foundational components in modern logistics and supply chain operations, providing safe and efficient ways to transport goods worldwide. Various materials are utilized in the construction of shipping pallets, each offering unique benefits and drawbacks based on operational requirements and industry standards. Selecting the right pallet material is critical for optimizing load stability, meeting hygiene regulations, reducing shipping costs, and ensuring reliable cargo handling across different industries.
Wooden pallets continue to dominate the shipping and warehousing industries due to their versatility and accessibility. They are the industry standard for transporting bulk products, industrial materials, furniture, sealed goods, and non-perishable items. Renowned for their durability and load-bearing capacity, wooden pallets are both cost-effective and simple to repair, contributing to their enduring popularity in supply chain management. Typically constructed from hardwood species such as oak or softwoods like pine, these pallets offer a naturally high-friction surface for enhanced safety during forklift or pallet jack handling.
However, wooden pallets can be heavy, leading to higher freight costs and making manual handling more labor-intensive. Their organic, porous structure can attract insect infestations such as termites, and they are susceptible to moisture damage, mold, corrosion, and chemical contamination. For industries such as food processing or pharmaceuticals, this can necessitate frequent sanitization or treatments like varnishing or heat treating. Furthermore, wood pallets may not comply with international shipping requirements without proper certification. To address performance and compliance limitations, engineered variations have been developed:
Plywood pallets are manufactured from multiple plies or sheets of wood veneer bonded with adhesive. Lighter than traditional wooden pallets, they are ideal for air freight and transporting light to medium loads. Pressure-treated plywood enhances protection against pests and microbial growth. Plywood pallets are valued for their dimensional stability, uniform strength, and consistent quality, making them appropriate for export shipping where adherence to ISPM-15 regulations is crucial.
Engineered molded wood pallets, also called composite or presswood pallets, are manufactured by fusing wood fibers, sawdust, shavings, or recycled wood with resin. Through high heat and pressure, the mixture is molded into standardized forms, resulting in pallets that are lighter but equal in strength to traditional models. They are commonly used for export due to their compliance with the International Plant Protection Convention (IPPC) ISPM-15 standards, ensuring the elimination of pests and pathogens. These pallets display a certification stamp to indicate international phytosanitary compliance, essential for global trade logistics and container shipping.
The IPPC ISPM-15 Certification Stamp includes the following elements:
As with standard wood pallets, molded wood variants can absorb moisture if exposed to outdoor elements. For warehousing efficiency and to prolong service life, indoor storage or protective covering is recommended.
Presswood pallets, made from compressed wood particles or recycled materials, are known for their lightweight yet robust structure. They offer space-saving nestable designs, making them ideal for return logistics and e-commerce distribution. While cost-effective and customizable in size, presswood pallets remain prone to moisture absorption, limiting their suitability in certain supply chains dealing with humidity fluctuations.
Plastic pallets, manufactured from advanced polymer materials, are increasingly favored for their lightweight, durable, and hygienic properties. Leading industries such as pharmaceuticals, food & beverage manufacturing, and electronics often specify plastic pallets to ensure clean, contamination-free transport and compliance with health and safety standards. These pallets are manufactured using various methods—rotational molding, thermoforming, blow molding, and injection molding—to produce customized solutions for automated warehouses and export shipments. Plastic pallets are resistant to corrosion, chemical exposure, and do not harbor bacteria or absorb moisture, making them optimal for closed-loop logistics and cold storage environments.
The commonly used polymeric plastic materials include:
PET plastics are highly favored for lightweight export pallets due to their cost-efficiency, recyclability, and rigid structure. PET's resistance to moisture ingress and chemical vapor makes it suitable for pharmaceutical distribution and the food industry supply chain, where hygiene and sustainability are critical.
HDPE plastic, known for its impressive strength-to-density ratio and impact resistance, withstands environmental stresses during loading, transport, and long-term storage. HDPE pallets are commonly used in warehousing systems, chemical processing, and heavy-duty industrial applications, offering exceptional performance—even at elevated temperatures. Their resilience against hazardous chemicals adds value to sectors managing volatile cargo or hazardous goods.
PP plastic pallets are engineered for maximum rigidity, longevity, and resilience. Ideal for automated material handling and closed-loop systems, they excel under continuous torsional and bending loads. Though more expensive than HDPE pallets, PP options deliver value in environments prioritizing structural integrity and premium quality.
The use of recycled plastics in pallet production supports sustainability initiatives and reduces environmental impact. Recycled plastic pallets utilize HDPE, PP, blends, or advanced composite materials and can be crafted through processes such as injection molding, foam molding, extrusion, and rotational molding. The chosen manufacturing method, plastic type, and design parameters depend on the application, load requirements, and durability targets, making recycled pallets ideal for diverse industries seeking eco-friendly pallet solutions.
ACM pallets, made from 100% recycled polyolefins (PO), represent the leading edge of sustainable pallet technology. The integration of post-industrial and post-consumer plastics results in a strong, reusable, and affordable pallet option. ACM is popular with retailers and manufacturers seeking "one-way" or single-use pallets that offer cost parity with wood while driving progress toward zero-waste packaging and circular supply chains.
Metal pallets are engineered for specialized use in demanding sectors such as military logistics, automotive supply chains, manufacturing, industrial storage, and environments requiring ultra-high durability. Constructed from high-grade materials including aluminum, carbon steel, and stainless steel, metal pallets excel at supporting extremely heavy loads, meeting fire safety codes, and resisting corrosion, chemicals, and harsh weather. They are particularly valuable for high-value or hazardous materials requiring uncompromised strength and resilience.
The initial investment in metal pallets is typically higher than that for wood or plastic alternatives, but their extended service life, ease of cleaning, and compliance with sanitation protocols offer long-term ROI, especially in regulated supply chains. However, their increased weight can raise handling and shipping costs, and repairs may require specialized skills and equipment.
For warehouse managers and logistics planners, the decision to use metal pallets hinges on unique operational requirements, such as repeated re-use, long-term storage of pre-assembled assemblies, or Meeting ISO standards for materials handling.
Paper pallets, also known as corrugated pallets, have gained traction among environmentally responsible companies seeking lightweight, cost-conscious, and easily recyclable solutions. Constructed from engineered paper board sheets, corrugate, or reinforced paper, these pallets carry the advantage of easy customization and safety—without nails, staples, or sharp edges. Ergonomically designed with integrated runners and top sheets, they are ideal for export, one-way shipping, product displays, and air freight where weight reduction is essential for lowering shipping fees and carbon emissions.
Fully recyclable and compliant with Occupational Safety and Health Administration (OSHA) standards, paper pallets typically weigh 13-16 lbs, around two-thirds less than standard wood pallets. Their low weight, improved workplace safety, and adaptability make them popular in retail, packaging, point-of-sale displays, and fast-moving consumer goods (FMCG) distribution. Paper pallets, however, have lower load-bearing capacity and are more susceptible to damage from moisture, high humidity, or extreme temperature, which can restrict usage in certain supply chains.
When evaluating paper pallets, logistics coordinators and purchasing managers should consider the specific environment—balancing sustainability goals, cargo weight, and supply chain risk management to make the most appropriate selection.
When selecting the optimal pallet material for your business, consider criteria such as cargo type, load weight, hygiene requirements, cost constraints, environmental regulations, compliance with IPPC ISPM-15 for export, and intended logistics application (closed-loop vs. open-loop systems). Wooden pallets remain the go-to for general warehousing and bulk freight, while plastic pallets excel in industries prioritizing hygiene and automation. Metal pallets are the preferred choice for heavy-duty, high-value, or hazardous shipments, and paper pallets appeal to those aiming for sustainability and lower transport costs.
For buyers and facility managers, understanding the unique features and limitations of each shipping pallet material increases operational efficiency, reduces product damage, and ensures regulatory compliance. Consulting with leading pallet manufacturers or suppliers is highly recommended for custom pallet solutions, purchase guidance, and to navigate current trends in sustainable and reusable shipping platforms.
Pallets can be categorized based on various factors including their support structure, number of entry points, deck configurations, and specific features and design elements. These aspects are crucial when selecting the appropriate pallet for a given application.
The mode of support between the top and bottom deck boards is crucial to the design of a pallet. Pallets are generally classified as either stringer pallets or block pallets:
The top and bottom decks of stringer pallets are connected by longitudinal pieces known as stringers. Typically, two stringers are placed on opposite sides of the pallet, with one or two additional stringers installed in parallel to the outer ones, positioned in the middle.
Block pallets feature twelve vertical supports called blocks, which uphold the top and bottom decks. These blocks are placed at the four corners, the center of each side, and the midpoints of the pallet.
Pallets can also be categorized based on the number of entry points where handling equipment, such as forklifts or pallet jacks, can access them:
These pallets offer access from all four sides, optimizing handling efficiency by reducing loading and unloading times, which is especially useful in confined spaces. Typically, block pallets are designed as four-way pallets. While they are the most robust and can support the highest weight capacities, they are also the heaviest and most costly option.
These pallets provide access from only two of their sides. This limited entry requires handling machinery to be positioned at a specific angle or orientation to manage the pallet. Typically, stringer pallets are two-way pallets by default. However, it is possible to modify a two-way pallet into a four-way or partially four-way pallet by adding notches to the non-accessible sides. This modification allows for entry from additional sides but can compromise the pallet's strength and reduce its weight capacity compared to the original two-way design.
The top deck of a pallet is where the product is placed. Various deck configurations are available, each suited to different products and shipping conditions.
Open deck pallets, also referred to as ventilated pallets, feature a top deck with gaps or perforations. These openings reduce the pallet's weight and facilitate the drainage of liquids if the product is wet.
Solid deck pallets are designed with a continuous top deck board, lacking any gaps. This design is preferred for its hygiene and ease of cleaning, as it eliminates hard-to-reach areas. Solid deck pallets are also well-suited for transporting small items, as there are no spaces where products could fall through.
Double face pallets feature mesh or planks on both the top and bottom faces, enhancing the pallet's strength and ensuring even weight distribution. These pallets come in two variations: reversible and non-reversible. Reversible pallets have identical top and bottom decks, allowing them to be stacked with products on either side. Non-reversible pallets, on the other hand, have different configurations on each side, with the top deck typically having more planks to better support the product during placement.
Double wing pallets feature top and bottom decks that extend beyond the stringers or blocks, providing additional surface area. This design makes them suitable for transporting large or numerous items simultaneously.
CP pallets are custom-designed for the chemical industry and must comply with the Plastics European Council standards and CP specifications. The CP rating of a pallet reflects its dimensions, with sizes ranging from 29.92 inches by 44.88 inches to 44.88 inches by 44.88 inches.
The CP rating not only specifies the pallet's dimensions but also dictates the types of containers it can transport and its construction details. The different CP ratings include:
| Chemical Pallet (CP) Rating System | |
|---|---|
| Rating | Description |
| CP1 | Best for boxes and bags or sacks of raw materials - have no bottom deck board and fitted with runners. |
| CP2 | Used to transport canisters, boxes, and fiber drums - three runners. |
| CP3 | Ideally suited to transporting bags, barrels, and octabins - square with three runners. |
| CP4 | Designed for sacks of raw materials - three runners and wide lead or edge board. |
| CP5 | Made for transporting small boxes and cartons - smaller with three runners and no bottom deck. |
| CP6 | Best for sacks and boxes - has a bottom deck board. |
| CP7 | Used to transport sacks - can easily be stacked. |
| CP8 | Designed to transport sacks and octabins - square pallets with bottom deck boards with a gap in the center for drainage. |
| CP9 | Ideal for bulk containers and drums - same as CP8 without drainage hole. |
A range of features can be added to pallet designs to enhance convenience and ergonomic efficiency for shipping providers and warehouse staff. These features are particularly prevalent in plastic pallets, as they can be seamlessly integrated into the pallet during the manufacturing process.
Drum pallets are specifically designed for managing containers filled with liquids, oils, and hazardous chemicals during transport and storage. They feature a catch panel to contain leaks and spills, helping to prevent contamination of the workplace and the environment, and facilitating easier cleanup. Typically, a standard drum pallet can accommodate up to four 55-gallon drums.
Stackable pallets feature a flat, solid base that supports the stacking of products and other pallets, allowing for double stacking. This base provides enhanced stability, reducing the risk of slipping or tipping when pallets are stacked, whether they contain products or are empty. These pallets are commonly used in warehouses where diverse stacking configurations and heavy loads are common.
Nestable pallets are designed with legs that fit into the legs and top of other nestable pallets, allowing for compact stacking. This feature enables efficient storage by reducing the space needed during return trips and in warehouse storage. However, this design means that nestable pallets do not have a completely smooth, flat surface.
Rackable pallets are designed to support heavier loads with enhanced load capacity. These pallets are made from plastics through injection, rotational, or foam molding processes, which add reinforcement for handling larger weights. Typically, rackable pallets are available in the standard size of 48 x 40 inches to fit into conventional pallet racks.
To ensure a secure fit on warehouse racks, rackable pallets feature grooves or ridges on their underside and are engineered to maximize storage space utilization. Light-duty rackable pallets with specialized designs have received approval from the Federal Drug Administration (FDA) and the United States Department of Agriculture (USDA) for use with pharmaceuticals, meat, food products, and medical devices.
Pallet sizes are standardized to simplify material handling across various equipment and vehicles. These standards facilitate fair agreements and compatibility within the supply chain, thereby easing global trade. Various organizations and associations around the world regulate pallet sizes. The most widely recognized among them are:
The table below outlines the six ISO-approved pallet dimensions, which serve as standard sizes for many regions. These dimensions are specified in ISO Standard 6780:2003, which covers Flat Pallets for Intercontinental Materials Handling – Principal Dimensions and Tolerances.
| Dimensions in mm (W x L) | Dimensions in inches (W x L) | Regions most used in |
|---|---|---|
| 1016 x 1219 | 40 x 48 | North America |
| 1000 x 2000 | 39.37 x 47.24 | Europe, Asia |
| 1165 x 1165 | 45.9 x 45.9 | Australia |
| 1067 x 1067 | 42 x 42 | North America, Europe, Asia |
| 1100 x 1100 | 43.3 x 43.3 | Asia |
| 800 x 1200 | 31.5 x 47.24 | Europe |
There are pallet sizes from GMA and EPAL which were adapted and recognized by the ISO.
GMA sanctions the standard dimensions of pallets used for handling goods within North America. This standard tailor fits the pallet sizes to industry-specific needs. Some of the pallet sizes in the GMA standard have counterparts in the ISO standard.
| Dimensions in mm | Dimensions in inches | Production Rank | Industry |
|---|---|---|---|
| (W x L) | (W x L) | ||
| 1016 x 1219 | 40 x 48 | 1 | Grocery, many others |
| 1067 x 1067 | 42 x 42 | 2 | Telecommunications, Paint |
| 1219 x 1219 | 48 x 48 | 3 | Drums |
| 1219 x 1016 | 48 x 40 | 4 | Military, Cement |
| 1219 x 1067 | 48 x 42 | 5 | Chemical, Beverage |
| 1016 x 1016 | 40 x 40 | 6 | Dairy |
| 1219 x 1143 | 48 x 45 | 7 | Automotive |
| 1118 x 1118 | 44 x 44 | 8 | Drums, Chemical |
| 914 x 914 | 36 x 36 | 9 | Beverage |
| 1219 x 914 | 48 x 36 | 10 | Beverage, Shingles, Packaged Paper |
| 889 x 1156 | 35 x 45.5 | Unknown | Military ½ ISO container, fits 36" standard doors |
| 1219 x 508 | 48 x 20 | Unknown | Retail |
EPAL pallet sizes, also known as EUR pallets, are designed to comply with export specifications within the European Union. Certain pallet sizes in the EPAL standard align with those in the ISO standard.
| EURO Pallet Type | Dimensions (W x L x D) | ISO Alternative |
|---|---|---|
| EUR 1 or EUR | 800 mm × 1200 mm 31.50 in × 47.24 in |
ISO 1 |
| EUR 2 | 1200 mm × 1000 mm 47.24 in × 39.37 in |
ISO 2 |
| EUR 3 | 1000 mm × 1200 mm 39.37 in × 47.24 in |
|
| EUR 6 | 800 mm × 600 mm 31.50 in × 23.62 in |
ISO 0, half the size of EUR |
| 600 mm × 400 mm 23.62 in × 15.75 in |
quarter the size of EUR | |
| 400 mm × 300 mm 15.75 in × 11.81 in |
one-eighth the size of EUR |
International Standards for Phytosanitary Measures No. 15 (ISPM-15) is the "Regulation of wood packaging material in international trade." This set of measures, established by the International Plant Protection Convention (IPPC), aims to control the introduction and spread of invasive species through improperly processed and contaminated wood. Raw wood, whether from living or dead trees, may carry pests such as bugs and beetles, as well as pathogens. The spread of these organisms can harm biodiversity. Adopted by numerous countries worldwide since 2002, ISPM-15 is continuously updated to address these concerns.
ISPM-15 applies to wooden pallets and other packaging materials like crates and dunnage with a thickness greater than 6 mm, using coniferous softwood and non-coniferous hardwood. However, the following wooden articles, which present a low risk of pest infestation, are exempt from this standard:
Raw wood used in the construction of wooden pallets must be debarked, regardless of the treatment method employed. Debarking is essential to prevent re-infestation while the wood awaits further processing. Only small pieces of bark are permitted, specifically those less than 3 cm wide or, if wider than 3 cm, with a total surface area of less than 50 square centimeters on each piece.
Debarking should be completed prior to treatment with methyl bromide or sulfuryl fluoride, as bark can interfere with the effectiveness of these treatments. For heat treatment processes, bark may be removed either before or after the heating process.
Below are examples of various treatment methods:
Treatment procedures, conducted by authorized providers, are regulated and overseen by the national plant protection organization (NPPO) of both the importing and exporting countries.
An IPPC mark is applied by the treatment providers to treated wood to certify it has undergone the approved procedures outlined by ISPM-15. The marking consists of:
The image above shows an example of an IPPC mark, though it may appear in various forms, provided it includes all the required elements of the official mark.
Wooden pallets that have been treated according to ISPM-15 standards and have not been repaired or modified can be reused without additional treatment. However, if a third of the wooden parts are replaced with raw wood during repairs, the pallet is classified as re-manufactured and must undergo re-treatment.
Pallets constructed from plastic, metal, and paper are not subject to this regulation and do not need treatment procedures. However, regular cleaning and disinfection are essential, particularly for pallets used in handling food, beverages, agricultural products, and pharmaceuticals. For plastic pallets, cleaning methods such as high-pressure washing, power washing, and manual washing are commonly used.
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