Custom Pallet Solutions Built Around Your Business
When off-the-shelf pallets do not fit, we design and build solutions that do. Custom sizes, heat treatment, branded pallets, and fully managed pallet programs, all tailored to your exact requirements.
Six Ways We Go Beyond Standard
Every business has unique pallet needs. From one-off custom builds to comprehensive management programs, we have the expertise and capability to deliver exactly what you need.
Custom Pallet Design
Need a pallet that does not exist off the shelf? We design and manufacture pallets to your exact specifications. Custom dimensions, load ratings, deck configurations, and material choices. Perfect for products with unique footprints, unusual weight distributions, or specialized handling requirements.
Specialty Sizes
Beyond the standard 48x40, we build pallets in virtually any dimension. Oversized pallets for machinery, half-pallets for retail displays, quarter-pallets for point-of-sale, and micro-pallets for small shipments. If you can measure it, we can build it.
Heat Treatment (ISPM-15)
International shipping requires ISPM-15 compliant pallets. We operate our own heat treatment facility, ensuring your pallets meet the 56 degrees Celsius core temperature for 30 minutes standard. Every treated pallet receives the official IPPC stamp for customs clearance worldwide.
Branded Pallets
Turn your pallets into a branding opportunity. We offer custom stenciling, burn branding, and paint marking with your company logo, name, or tracking codes. Ideal for pool pallets that circulate between your facilities and customers.
Pallet Management Programs
Let us manage your entire pallet operation. We track inventory, schedule replenishment, handle repairs, coordinate logistics, and provide detailed reporting. One monthly invoice, zero headaches. Free up your team to focus on your core business.
Consulting & Advisory
Not sure what you need? Our pallet specialists will visit your facility, analyze your operations, and recommend the most cost-effective and sustainable pallet strategy. We have helped hundreds of businesses optimize their pallet spend and reduce waste.
From Idea to Finished Product: The Full Walkthrough
Our six-stage design process ensures every custom solution meets your exact specifications. Each stage includes client review and approval, so there are never any surprises.
Initial Consultation & Needs Assessment
Every custom project begins with a thorough discovery conversation. We learn about your products, your shipping environment, your handling equipment, and your budget. We ask questions like: What are the dimensions and weight of the products being palletized? How will the pallet be handled -- by forklift, pallet jack, or automated systems? Does the pallet need to be rackable, stackable, or both? Are there regulatory requirements such as ISPM-15 or food-grade compliance? What is the expected number of use cycles? Understanding these details upfront prevents costly design changes later and ensures the final product performs exactly as needed.
CAD Design & Engineering
Our design team creates detailed Computer-Aided Design (CAD) drawings of your custom pallet. These drawings specify every dimension, board thickness, stringer or block configuration, fastener type and placement, and any special features such as notches, chamfers, or reinforcement points. For pallets with significant load-bearing requirements, we perform engineering calculations to determine the appropriate lumber species, board dimensions, and fastener patterns needed to meet your target load capacity with appropriate safety margins. You receive the CAD drawings for review and approval before we move to prototyping.
Prototyping & Sample Production
Before committing to full production, we build a small batch of sample pallets, typically 3 to 5 units, for your hands-on evaluation. These prototypes are built to the exact specifications from the approved CAD design, using the same materials and construction methods that will be used in production. We encourage you to load-test the prototypes in real-world conditions: put them on your racking, run them through your conveyors, load them with actual products, and ship them to a customer. Real-world testing reveals issues that no amount of design work can anticipate.
Testing & Design Refinement
After you have tested the prototypes, we meet to review the results. Did the pallet fit your racking system correctly? Was the load capacity adequate? Did the forklift entries align with your equipment? Were there any issues with product fit or stability? Based on your feedback, we refine the design. This might involve adjusting board spacing, changing lumber species for better load performance, adding reinforcement in high-stress areas, or modifying dimensions to better fit your storage systems. We iterate until the design is exactly right. Most projects require one round of refinement; complex projects may need two.
Production & Quality Control
Once you approve the final design, we move to full production. Our production team builds each pallet to the approved specification using jigs and templates that ensure dimensional consistency across every unit. Every pallet passes through our multi-point quality inspection process, which verifies dimensions, structural integrity, fastener placement, and overall finish quality. For large production runs, we perform in-process quality checks at regular intervals to catch any drift from specification early. Production capacity allows us to manufacture 200 to 500 custom pallets per day depending on complexity.
Delivery & Ongoing Support
We deliver your custom pallets on the schedule you need, whether that is a single bulk delivery or a recurring weekly supply. Your custom pallet specifications are stored permanently in our system, so reorders are as simple as a phone call or email specifying the quantity needed. As your product line evolves or your requirements change, we adjust the design accordingly. Your dedicated account manager monitors your usage patterns and proactively reaches out when it is time to reorder, ensuring you never face a production delay due to pallet shortages.
Material Options Comparison
The right material depends on your load requirements, budget, regulatory environment, and number of use cycles. Here is a detailed comparison of the materials we work with to help you make an informed choice.
| Material | Type | Strength | Weight | Cost | Best For |
|---|---|---|---|---|---|
| Southern Yellow Pine (SYP) | Softwood | Good | Light to Medium | Most Affordable | General shipping, single-use, export pallets |
| Spruce-Pine-Fir (SPF) | Softwood | Good | Light | Affordable | Lightweight shipments, air freight, retail displays |
| Red Oak | Hardwood | Excellent | Heavy | Premium | Heavy loads, multi-trip pallets, racking systems |
| Maple | Hardwood | Excellent | Heavy | Premium | Premium applications, pharmaceutical, clean rooms |
| HDPE Plastic | Plastic | Very Good | Medium | High Initial, Low Lifecycle | Closed-loop systems, hygiene-critical, automated handling |
| Presswood / Molded | Composite | Moderate | Light | Moderate | Export, air freight, one-way shipping |
Southern Yellow Pine (SYP)
Softwood | Most Affordable
The most commonly used pallet lumber in North America. Accepts heat treatment well for ISPM-15 compliance. Provides good strength-to-weight ratio at the lowest cost point.
Spruce-Pine-Fir (SPF)
Softwood | Affordable
Lighter than SYP with comparable strength for lighter loads. Excellent for applications where pallet weight affects shipping costs. Clean appearance makes it popular for retail-facing applications.
Red Oak
Hardwood | Premium
The industry standard for heavy-duty pallets. Outstanding load-bearing capacity and resistance to impact damage. Lasts 7 to 10 repair cycles, making it the most cost-effective choice over the long term for multi-use applications.
Maple
Hardwood | Premium
Dense, smooth grain with excellent resistance to splintering. Preferred for pharmaceutical and food-grade applications where surface cleanliness matters. Minimal grain raise even after repeated washing.
HDPE Plastic
Plastic | High Initial, Low Lifecycle
Impervious to moisture, chemicals, and insects. Does not require heat treatment for international shipping. Lasts 100+ trips in closed-loop systems. Ideal for automated handling systems that require exact dimensional consistency.
Presswood / Molded
Composite | Moderate
Made from recycled wood fibers compressed under heat and pressure. ISPM-15 exempt because the manufacturing process eliminates pests. Nestable design reduces storage space by up to 75% compared to stacked wood pallets.
Custom Solutions We Have Built
Every custom project tells a story of a problem solved. Here are three detailed examples of how our custom solutions addressed real business challenges and delivered measurable results.
Precision Optics Northwest
Electronics / Optical Equipment
The Challenge
Precision Optics ships high-value optical instruments weighing between 15 and 180 pounds in custom foam packaging. Their standard 48x40 pallets were too large for many of their products, resulting in wasted shipping space and higher freight costs. Additionally, the optical instruments are extremely sensitive to vibration and shock, requiring a pallet design that minimizes transit damage.
Our Solution
We designed a family of three custom pallet sizes (24x24, 30x36, and 36x48) with anti-vibration features including rubber isolation pads at the stringer-to-deck board junctions and a double-layer deck design that distributes load forces more evenly. Each pallet also incorporated corner alignment blocks to lock the foam packaging in position and prevent shifting during transit.
Results
62% reduction in transit damage claims
23% reduction in outbound freight costs from right-sized pallets
Custom sizes fit UPS and FedEx dimensional pricing thresholds
Branded with company logo and QR tracking code for pool management
Cascade Brewing Collective
Food & Beverage
The Challenge
Cascade Brewing distributes craft beer to retailers across the Pacific Northwest using standard pallets. Their challenge was twofold: they needed pallets strong enough to safely hold 2,400 pounds of bottled and canned product, and they needed ISPM-15 certified pallets for occasional exports to Canada and Japan. Their existing supplier could not guarantee heat-treated pallets on the short timelines required for international orders.
Our Solution
We built a custom heavy-duty pallet using red oak stringers and SYP deck boards, rated for 3,000 pounds static load. All pallets are heat treated and ISPM-15 stamped at time of manufacture, eliminating the need for separate treatment runs when international orders come in. We set up a weekly subscription program delivering 150 pallets every Monday morning to their Portland brewery, with additional pallets available on 24-hour notice for export orders.
Results
Zero pallet failures in first 14 months of service
100% ISPM-15 compliance ready at all times, no pre-order lead time needed
Weekly subscription eliminated procurement overhead for warehouse team
18% cost savings compared to previous certified pallet supplier
Valley Agricultural Cooperative
Agriculture
The Challenge
Valley Agricultural Cooperative handles seasonal produce shipments that swing from 200 pallets per week in winter to over 2,000 per week during peak harvest from July through October. Their previous pallet supplier could not scale up fast enough during peak season, causing shipping delays that cost the cooperative thousands of dollars in spoiled produce. They also needed multiple pallet sizes for different produce types.
Our Solution
We designed a comprehensive pallet management program with three custom sizes: a standard 48x40 for boxed produce, a half-pallet (24x40) for farmers market deliveries, and an oversized 60x48 for bulk bin shipments. We pre-build and warehouse 3,000 pallets in our facility during Q1 and Q2 to guarantee availability during peak season. Deliveries scale automatically based on the cooperative's weekly order volume, managed by a dedicated account manager.
Results
Zero stockouts during three consecutive harvest seasons
Three custom sizes reduced product damage by 31%
Pre-built inventory eliminated lead time delays entirely
Single-vendor consolidation reduced administrative burden by 50%
Minimum Order Quantities
Minimum order quantities vary by project type and complexity. Here is a clear breakdown so you know what to expect before reaching out. We are always willing to discuss exceptions for unique situations.
Standard Custom Sizes
Custom dimensions using standard lumber. No special engineering or tooling required. Most common type of custom order.
Engineered / Heavy-Duty
Pallets with specific load ratings, reinforced construction, or unusual configurations requiring engineering calculations.
Prototypes & Samples
Small sample runs for testing and evaluation. Pricing is per-unit at a higher rate than production runs.
Heat Treatment Only
ISPM-15 heat treatment and stamping for pallets you supply. No minimum for existing customers.
Branded Pallets
Custom stenciling, burn branding, or paint marking. First order includes one-time setup for branding templates.
Management Programs
Minimum monthly volume for full managed pallet programs. Includes all services: procurement, repair, logistics, reporting.
Production Turnaround by Order Size
Turnaround time depends on order size, complexity, and service type. This table gives you realistic expectations for each combination so you can plan your procurement timeline accordingly.
| Order Size | Standard Custom | Engineered | Heat Treatment | Branded |
|---|---|---|---|---|
| Small (50-99 pallets) | 5-7 days | 7-10 days | 24-48 hours | 5-7 days |
| Medium (100-499 pallets) | 7-10 days | 10-14 days | 24-48 hours | 7-10 days |
| Large (500-999 pallets) | 10-14 days | 14-21 days | 48-72 hours | 10-14 days |
| Enterprise (1,000+ pallets) | 14-21 days | 21-30 days | 3-5 days | 14-21 days |
| Rush / Expedited | 3-5 days | 5-7 days | Same day | 3-5 days |
All turnaround times are measured from design approval to production completion. Delivery time is additional and depends on your location. Rush and expedited service is available for most order types at a surcharge. Contact us for exact timelines based on your specific project.
Heat Treatment for International Shipping
If your pallets cross international borders, ISPM-15 compliance is mandatory. We operate a fully certified heat treatment facility and stamp every treated pallet with the official IPPC mark.
What is ISPM-15?
International Standards for Phytosanitary Measures No. 15 is a global regulation that requires wood packaging materials used in international trade to be treated to eliminate pests. The most common treatment method is heat treatment (HT), where the wood core temperature reaches 56 degrees C for at least 30 minutes.
Why Does It Matter?
Without ISPM-15 compliant pallets, your international shipments can be rejected at the border, quarantined, or destroyed. Non-compliance leads to costly delays, fines, and damaged business relationships. Proper certification prevents all of this.
Our Certification
We are a licensed ISPM-15 treatment facility, authorized to apply the official IPPC mark. Every treated pallet is stamped with the internationally recognized certification that customs authorities around the world accept.
Turnaround Time
Standard heat treatment takes 24 to 48 hours from the time pallets arrive at our facility. For rush orders, we offer same-day treatment when capacity allows. Contact us to discuss your timeline.
Pallet Management Programs
Outsource your entire pallet operation to us. One partner, one invoice, zero headaches. We handle everything from procurement to disposal so your team can focus on what they do best.
Inventory Tracking
We monitor your pallet inventory in real time, tracking quantities on hand, in circulation, and in repair. You always know exactly where you stand.
Automatic Replenishment
When inventory drops below your target threshold, we automatically schedule production and delivery. No manual reordering, no stockouts.
Repair & Maintenance
Damaged pallets are collected, repaired, and returned to your pool. We handle the entire repair lifecycle without you lifting a finger.
Monthly Reporting
Receive detailed monthly reports on pallet usage, costs, repair rates, and environmental impact metrics. Data-driven insights to optimize your program.
Single Invoice
One consolidated monthly invoice covers all pallet services: purchasing, repair, logistics, and management. Simplified accounting and clear cost visibility.
Dedicated Account Manager
Your account manager is your single point of contact for everything pallet-related. They know your business, your preferences, and your priorities.
Beyond Standard Dimensions
Standard pallets work for standard products. But when your cargo is anything but standard, we build to fit.
Oversized
60" x 48" and up
Heavy machinery, industrial equipment, large assemblies
Half Pallets
24" x 40" / 24" x 20"
Retail displays, point-of-sale, small shipments
Euro Pallets
31.5" x 47.25" (800x1200mm)
European trade, international shipping, ISO compliance
Custom Any-Size
Your specs, our build
Unique products, specialized racking, odd-shaped cargo
Custom Solutions FAQ
What is the minimum order quantity for custom pallets?
For standard custom sizes, our minimum is 50 pallets. For highly specialized designs requiring unique tooling or engineering, we typically start at 100 units. For prototyping and testing, we can produce as few as 5 samples.
How long does it take to go from design to delivery?
A straightforward custom size can be designed, prototyped, and in production within one to two weeks. More complex projects with engineering requirements typically take three to four weeks from initial consultation to first delivery.
Can you match an existing pallet we are already using?
Absolutely. Send us a sample or detailed measurements and we will replicate it. This is common when a current supplier becomes unavailable or when you want to consolidate vendors. We match or exceed the original specification.
How does the pallet management program pricing work?
Management program pricing is customized based on your volume, service requirements, and complexity. Most programs use a per-pallet or flat monthly fee structure. We provide a detailed proposal after the initial consultation.
Do you offer heat treatment for pallets we did not purchase from you?
Yes. Our heat treatment facility is open to any business that needs ISPM-15 compliance. Bring us your pallets and we will treat and stamp them. Volume discounts are available for large batches.
Can branded pallets include barcodes or QR codes?
Yes. Beyond logos and text, we can apply barcodes, QR codes, and sequential numbering for pallet tracking. This is particularly useful for pallet pooling systems and supply chain visibility programs.
Have a Unique Pallet Challenge?
We love solving problems that off-the-shelf pallets cannot. Tell us what you need and we will design a solution that works. From a quick consultation to a full custom design and build, we are here to make it happen. No challenge is too unusual and no order is too specialized.