Pallet Types & Materials
A comprehensive guide to every type of pallet we offer, from traditional wood stringer pallets to high-performance plastic and metal options, plus a full range of accessories.
Wood Pallets
Wood pallets account for approximately 90-95% of all pallets in use in the United States. They remain the dominant choice because of their low cost, easy repairability, high recyclability, and wide availability. Wood pallets can be built to virtually any specification and are compatible with all common handling equipment.
The two primary construction methods for wood pallets are stringer and block designs. Each has distinct advantages depending on your application. We carry both types in all standard sizes and quality grades, plus we can build custom configurations to meet your exact specifications.
Stringer Pallets
Stringer pallets are the most common type of wood pallet in North America. They use two or three long boards (called “stringers”) running between the top and bottom deck boards to provide structural support. The stringers are typically 2x4 or 3x4 lumber and are notched to allow partial four-way fork entry.
The standard 48x40 GMA (Grocery Manufacturers Association) pallet is a stringer-style pallet and is by far the most widely used pallet specification in the United States. Stringer pallets are lighter and less expensive than block pallets, making them ideal for one-way shipping and general warehousing.
Pros
- Lower cost per unit
- Widely available
- Easy to repair
- Lighter weight
- Simple design
Cons
- Partial 4-way entry only
- Lower load capacity vs block
- Less stable for racking
- Stringers can crack
Best for: General warehousing, one-way shipping, retail distribution, grocery, and any application where cost efficiency is the primary concern.
Block Pallets
Block pallets (also called four-way pallets) use cylindrical or rectangular wooden blocks between the top and bottom deck boards, typically with nine blocks arranged in a 3x3 pattern. Perpendicular stringer boards connect the blocks, and the top and bottom decks are nailed to both the blocks and stringers.
This construction provides true four-way entry, meaning forklifts and pallet jacks can access the pallet from all four sides without any restriction. Block pallets are generally stronger and more rigid than stringer pallets, and they are the standard design in Europe (EUR/EPAL pallets are all block style).
Pros
- True 4-way fork entry
- Higher load capacity
- Better for racking systems
- More durable overall
- European standard
Cons
- Higher cost per unit
- Heavier than stringer
- More complex to repair
- Requires more lumber
Best for: Automated warehouse systems, heavy loads, pallet racking, international shipping, and applications requiring full four-way access.
Double-Face Pallets
Feature deck boards on both top and bottom surfaces, providing a flat surface on each side. Reversible pallets have identical top and bottom decks, while non-reversible have different board spacing. Double-face pallets are excellent for racking because the bottom deck distributes weight across the rack beams. They are common in warehouse and distribution operations where pallets are frequently handled and need maximum durability.
Common use cases: Warehouse racking, heavy-duty storage, long-term inventory, distribution centers
Double-Wing Pallets
The top and/or bottom deck boards extend beyond the stringers or blocks, creating overhang (wings) on two or four sides. This extra surface area provides better support for loads that are slightly larger than the pallet body. Wing pallets are common in the paper and beverage industries, where product dimensions may slightly exceed standard pallet footprints. The wings also provide convenient grip points for banding and wrapping.
Common use cases: Paper industry, beverage distribution, oversized loads, drum and barrel shipping
Solid Deck Pallets
Instead of spaced deck boards, solid deck pallets use plywood, oriented strand board (OSB), or tightly butted boards to create a continuous surface. This eliminates gaps where small items could fall through and provides a smooth, uniform surface for all load types. Solid decks are popular for small parts, bags, and irregularly shaped cargo. They also reduce product contamination risk and provide better weight distribution.
Common use cases: Small parts shipping, bagged goods, pharmaceutical, food processing, cleanroom environments
Wood Species Used in Pallet Construction
The type of wood used in pallet construction significantly impacts performance, weight, cost, and durability. Most pallets in North America are made from softwoods due to their availability and lower cost.
Softwoods (Most Common)
- Southern Yellow Pine (SYP) - Strongest softwood; most popular for pallets in the eastern US
- Spruce-Pine-Fir (SPF) - Lightweight, widely available in Pacific Northwest
- Douglas Fir - Strong and stiff; popular in western US pallets
- Hemlock - Economical option, moderate strength
Hardwoods (Premium)
- Oak - Extremely strong and durable; heavy; used for export and heavy-duty
- Maple - Hard, dense, excellent wear resistance
- Alder - Lighter hardwood, good balance of strength and weight
- Poplar / Aspen - Lightest hardwoods; sometimes used for economy pallets
Plastic Pallets
Plastic pallets have seen rapid growth over the past two decades, now representing approximately 5-7% of the North American pallet market. They are especially popular in industries with strict hygiene requirements, closed-loop supply chains, and automated handling environments. Plastic pallets are immune to moisture, insects, and mold, making them exempt from ISPM-15 phytosanitary treatment requirements for international shipping.
Plastic pallets are manufactured using injection molding, structural foam molding, thermoforming, rotational molding, or profile extrusion. The choice of manufacturing method, resin type, and structural design all influence the pallet's performance characteristics, weight capacity, and price point.
HDPE (High-Density Polyethylene)
HDPE is the most common resin used in plastic pallets. It offers an excellent balance of strength, chemical resistance, and impact resistance. HDPE pallets are resistant to acids, alkalis, and most solvents, making them suitable for chemical and food processing environments. They perform well in cold storage (down to -40 degrees F) and are FDA approved for food contact.
Pros
- Excellent chemical resistance
- FDA approved for food contact
- Works in freezer conditions
- Impact resistant
- 100% recyclable
Cons
- Higher initial cost than wood
- Can become brittle in extreme cold
- Difficult to repair
- Lower stiffness than PP
Best for: Food processing, cold storage, pharmaceutical, chemical handling, export shipping
PP (Polypropylene)
Polypropylene pallets are stiffer and more rigid than HDPE, making them better suited for heavy static loads and pallet racking applications. PP has a higher melting point than HDPE, allowing it to withstand autoclaving and steam cleaning at higher temperatures. However, PP is less impact-resistant than HDPE, especially at cold temperatures, and may crack under sudden shock loading.
Pros
- Higher stiffness and rigidity
- Better for racking systems
- Higher heat resistance
- Can be autoclaved
- Good chemical resistance
Cons
- More brittle than HDPE
- Poor cold-temperature performance
- Higher cost
- Less impact resistant
Best for: Automated warehouses, pharmaceutical cleanrooms, high-temperature environments, pallet racking
Nestable Pallets
Nestable plastic pallets are designed with tapered legs or a nine-foot design that allows empty pallets to nest inside each other, dramatically reducing storage and return-shipping space. A stack of 25 nestable pallets may occupy the same height as 5-7 stacked standard pallets. This makes them the ideal choice for one-way shipping, export, and companies with limited storage space. Nestable pallets typically have lower weight capacities than structural pallets, with most rated between 1,500 and 2,500 pounds for dynamic loads.
Pros
- Saves 60-70% storage space when empty
- Lightweight (10-20 lbs typical)
- Lower shipping cost for returns
- ISPM-15 exempt
Cons
- Lower weight capacity
- Cannot be used in racking
- Less durable than structural
- Not suitable for heavy loads
Stackable / Rackable Pallets
Stackable (also called rackable) plastic pallets are built with a solid structure that allows them to be safely stored on warehouse racking systems and stacked when loaded. They typically use injection molding or structural foam processes to create a rigid, heavy-duty pallet capable of supporting 2,000 to 30,000+ pounds in static conditions. These pallets are designed for closed-loop supply chains where the pallet investment is recovered through hundreds of reuse cycles.
Pros
- High weight capacity (up to 30,000 lbs static)
- Compatible with pallet racking
- Extremely durable and long-lasting
- Consistent dimensions for automation
Cons
- Highest cost per unit ($50-$120+)
- Heavy (40-60 lbs)
- Cannot nest when empty
- Not cost-effective for one-way use
Metal Pallets
Metal pallets represent the pinnacle of pallet durability and load capacity. While they carry a higher upfront cost, metal pallets can last for decades and support extraordinarily heavy loads. They are commonly used in automotive manufacturing, military logistics, outdoor storage, and applications where fire resistance is critical. Metal pallets are fully recyclable and are exempt from ISPM-15 phytosanitary requirements.
Steel Pallets
Steel pallets are the strongest pallet option available, capable of supporting loads of 5,000 pounds or more in dynamic conditions. They are typically constructed from carbon steel or galvanized steel using welded or bolted construction methods. Common designs include corrugated steel decks, expanded metal decks, and tubular steel frames.
Steel pallets excel in harsh environments including outdoor storage, high-temperature zones, and applications where fire resistance is mandatory. They are commonly found in automotive assembly plants, military supply chains, and metal fabrication facilities. The main drawbacks are their weight (70-120 lbs per pallet) and susceptibility to rust if not galvanized or powder-coated.
Pros
- Highest load capacity
- Fireproof
- Decades-long lifespan
- Vermin & insect proof
- Fully recyclable (scrap value)
Cons
- Very heavy (70-120 lbs)
- High initial cost ($100-$200+)
- Rust risk without coating
- Can damage products if dropped
- Requires welding for repair
Aluminum Pallets
Aluminum pallets provide the durability and longevity benefits of metal at roughly half the weight of steel. They are naturally corrosion-resistant, making them ideal for outdoor storage, maritime shipping, and high-humidity environments without requiring additional coatings or treatments.
Aluminum pallets are particularly popular in the aerospace industry, air freight, and pharmaceutical cold chains. Their lighter weight reduces fuel costs in transportation, and their non-porous surface makes them easy to clean and sanitize. The primary drawback is cost: aluminum pallets are among the most expensive pallet options, though they hold strong resale and scrap value.
Pros
- Naturally rust-proof
- Half the weight of steel
- Excellent for air freight
- Easy to clean / sanitize
- High scrap & resale value
Cons
- Highest cost option
- Lower capacity than steel
- Can dent more easily
- Limited availability
- Specialized repair needed
Presswood & Composite Pallets
Presswood pallets (also called molded wood or compressed wood pallets) are manufactured by combining wood fibers, chips, or sawdust with resins and pressing them into shape under high heat and pressure. This manufacturing process eliminates insect infestation risk, making presswood pallets automatically compliant with ISPM-15 international shipping regulations without additional heat treatment or fumigation. They are an excellent, cost-effective choice for one-way export shipping.
Presswood Pallet Characteristics
Presswood pallets are typically lighter than conventional wood pallets (15-30 lbs versus 30-70 lbs), which reduces shipping costs. They nest when empty, saving up to 50% warehouse space. The molded construction creates consistent dimensions with no nails, screws, or splinters, reducing product damage and worker injury risk.
However, presswood pallets have lower weight capacities than conventional wood (typically 1,200-2,500 lbs dynamic) and cannot be repaired. They are also more susceptible to moisture damage than plastic or metal alternatives, and their lifespan is shorter (3-10 trips typically). They are best suited for one-way shipping, especially international export.
Pros
- ISPM-15 exempt (no HT needed)
- Lightweight (15-30 lbs)
- Nestable (saves storage space)
- No nails, screws, or splinters
- Made from recycled wood waste
- Consistent, precise dimensions
Cons
- Cannot be repaired
- Lower weight capacity
- Shorter lifespan (3-10 trips)
- Susceptible to moisture
- Limited size options
- Not suitable for racking
Composite Pallets
Composite pallets blend multiple materials to achieve specific performance goals. Common combinations include wood-plastic composites (WPC), fiberglass-reinforced plastic, and corrugated fiberboard with wood stringers. These hybrid designs aim to combine the best attributes of each material.
For example, a wood-plastic composite pallet offers better moisture resistance than pure wood with lower cost than pure plastic. Corrugated pallets with wood stringers provide a lightweight, recyclable option for lighter loads. Composite pallets are still a niche market but are growing as manufacturers develop new material combinations.
Corrugated Paper Pallets
Made entirely from heavy-duty corrugated cardboard, corrugated pallets are the lightest option available (typically 5-15 lbs). They are 100% recyclable in standard cardboard recycling streams and are ISPM-15 exempt. They are designed for air freight and light-duty one-way shipping where minimizing weight is critical.
Weight capacities range from 500 to 2,500 lbs depending on construction, but they should not be exposed to moisture or used in outdoor environments. Corrugated pallets are popular in the electronics and consumer goods industries for international air shipments.
Custom Pallets
When standard pallet configurations do not meet your needs, we build custom pallets to your exact specifications. Our custom pallet program covers non-standard dimensions, specialized materials, unique load requirements, branded pallets, and application-specific designs. Whether you need a pallet that is 3 inches tall for low-clearance environments or a 6-foot-wide platform for oversized equipment, we can engineer and manufacture a solution.
Custom Dimensions
Any length, width, and height combination. We regularly produce pallets from 12x12 inches up to 8x10 feet. Unusual aspect ratios, extra-thin profiles, and tall block configurations are all possible.
Specialized Load Support
Engineered for your specific load. We calculate stringer and deck board spacing, material thickness, and fastener patterns based on your product weight, shape, and stacking requirements.
Branded & Painted
Custom colors, logos, and markings applied to your pallets for brand visibility, theft deterrence, and easy identification in pooled environments. Heat branding and stenciling available.
Mixed Material
Combine materials for optimal performance. Wood frames with metal reinforcement, plastic decks on wood stringers, or any combination that meets your specific performance criteria.
Display Pallets
Attractive, finished pallets designed for retail display environments. Sanded, stained, or painted surfaces suitable for showroom floors and point-of-sale displays.
Specialty Applications
FDA-compliant food pallets, anti-static pallets for electronics, fire-retardant treated pallets, and corrosion-resistant pallets for chemical environments.
Have a custom pallet project in mind? We offer free design consultations and can typically produce prototypes within 5-7 business days.
Discuss Your Custom ProjectPallet Accessories
Maximize the functionality of your pallets with our comprehensive range of accessories. From collars that convert flat pallets into containers, to stretch wrap that secures loads during transit, we carry everything you need for a complete pallet solution.
Pallet Collars
Hinged wooden or plastic frames that stack on top of a standard pallet to create a rigid, reusable shipping box. Collars fold flat when not in use and can be stacked to create walls of any height. They eliminate the need for corrugated boxes and dramatically reduce packaging waste. Available in standard sizes (48x40, 48x45, 48x48) and custom dimensions. Each collar adds approximately 8 inches of wall height.
Standard heights: 8", available in multiples. Material: pine, HDPE. Hinges: galvanized steel.
Pallet Lids
Flat covers that sit on top of pallet collars or directly on loaded pallets to protect contents from dust, moisture, and debris during storage and transit. Available in plywood, corrugated plastic (Coroplast), and solid HDPE. Lids can include reinforcing ribs for stacking strength, ventilation holes for produce, and locking tabs for security.
Materials: plywood (5mm-12mm), Coroplast, HDPE. All standard pallet sizes.
Corner Protectors
L-shaped or U-shaped protectors that shield pallet corners and cargo edges from damage during handling and transit. Made from cardboard, plastic, or foam materials. Corner protectors prevent strap damage to products, stabilize stacked loads, and reduce crushing damage. Essential for protecting fragile goods like appliances, furniture, and electronics.
Materials: recycled cardboard, PE foam, recycled plastic. Various lengths and thicknesses.
Dividers & Separators
Horizontal and vertical partitioning systems that organize and protect individual items within a palletized load. Horizontal layer pads distribute weight between stacked layers. Vertical cell dividers create individual compartments for bottles, jars, and fragile items. Available in corrugated cardboard, plastic, and foam.
Types: layer pads, cell dividers, custom partitions. Material: corrugated, plastic, foam.
Stretch Wrap
Elastic plastic film used to unitize and secure loads on pallets. Stretch wrap holds products tightly to the pallet, provides tamper evidence, and protects against dust and moisture. Available in hand wrap rolls (for manual application) and machine rolls (for automated stretch wrappers). We carry clear, opaque, and UV-stabilized varieties.
Widths: 12"-20". Gauges: 60-120. Types: hand, machine, pre-stretched. Clear & opaque.
Strapping & Banding
High-strength bands used to secure heavy or irregularly shaped loads to pallets. Strapping is applied with tensioning tools and sealed with metal or plastic buckles. Available in polypropylene (PP) for light-medium loads, polyester (PET) for heavy loads, and steel for the heaviest applications. Strapping tools and seals also available.
PP: 1/2"-3/4", PET: 1/2"-1 1/4", Steel: 3/8"-2". Manual and pneumatic tools available.
Find Your Perfect Pallet
Not sure which pallet type is right for your application? Our team of pallet specialists is ready to help you evaluate your options and find the most cost-effective solution.