Different types of Pallet materials

Different types of Pallet materials

Pallets can be made by different types of materials. Here are some examples:

Wood Pallets

Most common because they represent a good balance of the five design parameters discussed above—they are strong, stiff, relatively durable, and inexpensive. Because wood pallets have been around so long, many packaging and material handling systems are “built” around the use and performance of wood pallets. Furthermore, wood pallets are easy to prototype using a computer aided design program called PDS that estimates pallet strength, stiffness, and service life. This program is available for wood pallets only.

Wood pallets are also easy to repair. In recent years, the pallet repair and remanufacturing industry has grown to accommodate approximately 233 million pallets per year. Some disadvantages of wood pallets are that they have metal fasteners (nails) that can potentially damage products. Wood pallets can also have splinters, moisture related problems, bugs, and sometimes significant performance variation between pallets.

Plastic Pallets

It is estimated that plastic pallets make up 2-4% of new pallet production in the US, or 15 million new plastic pallets per year. Plastic pallets cost anywhere from 3 to 6 times as much as wood pallets.

The most common plastic materials for pallets are HDPE, PP, and PVC. The most common manufacturing process is structural foam molding, but other processes include injection molding, profile extrusion, rotational molding, compression molding, and thermoforming.

General advantages of plastic pallets are high durability, cleanliness, no metal fasteners, bug free, weather resistance, and flexible design potential. Disadvantages include higher price, difficulty to prototype, low friction, low stiffness, lack of repair options, and fire safety ratings. Plastic pallets are most common in captive or closed loop warehouse environments supporting 2000 pounds or less. The automotive, dairy, pharmaceutical, USPS, and beverage industries commonly use plastic pallets.

In Japan and other Asian countries, it is estimated that plastic pallets make up 50% or more of the reusable pallet pools. Composite Wood Pallets Wood composites, such as plywood, OSB, particle board, and laminated veneer lumber, represent 2-4% of the pallet market. Beer pallets were a historical market for composite pallets. More recently, due to the implementation of international pest regulations that apply to pallets made of solid wood, composites pallets have become a desirable alternative for import/export use. Composites are exempt from pest regulations and often have a lower price than plastic or metal pallets.

Wood composite pallets are also durable, dry, provide complete pallet deck coverage, and are easy to prototype (they can also be designed using PDS). Some disadvantages are that they cost more than solid wood, are expensive to repair, less weather resistant than plastic or metal, and still require fasteners.

Paper Based Pallets

Paper pallets represent less than 1% of the market, and include corrugated, honeycomb, solid fiberboard, and molded pulp. In the case of containers, there has been dramatic shift over the years from wood to corrugated paperboard. This has not been the case for pallets. While a corrugated box is less expensive than a wood box, a paper pallet costs more than the equivalent wood pallet. Paper pallets mainly find acceptance within niche markets with light loads. Recently, new markets have opened, driven mostly by international pest regulations and increased airfreight shipping with weight-based charges.

The key advantages of paper pallets are that they are lightweight, easily recyclable, have a smooth deck surface, and are dry and bug free. Disadvantages include a price higher than wood, susceptibility to moisture, lack of stiffness with flexible loads, low durability, and low product protection.

Metal Pallets

Metal pallets make up less than 1% of the market. Materials include carbon steel, stainless steel, and aluminum. Of these, carbon steel offers excellent durability at the lowest cost. Stainless steel doesn’t require a paint coating, and is preferred for such applications as clean room environments. Aluminum offers the durability of metal at a lighter weight. Carbon steel units are relatively expensive compared to wood and stainless and aluminum cost about 2-3 times that of carbon steel. Long term costs, however, can be lower than wood.

General advantages of metal pallets are high strength and stiffness, excellent durability, bug free, no splinters, sanitary, and recyclable. Disadvantages include a higher initial price, significant weight, low friction, and susceptibility to rusting (carbon steel). Metal is primarily used in captive or closed loop environments where durability and product protection are key performance requirements. Metal units today are increasingly price competitive and lighter in weight. Primary industries that use metal pallets include automotive, pharmaceutical, lawn tractors, motorcycles, and tires.

While the majority of pallets are made of wood, pallets manufactured from plastic, metal, and paper can also be found. Each material has pros and cons (cost, environmental impact, etc.) depending on which industry is using the pallets and which variables it is trying to maximize or minimize.

Wooden pallets are the most common used pallets in the United States and in the world. It is estimated that 90% of all pallets are made of wood.

So why are 90% of all pallets made from wood? The answer: Wooden pallets are cheap compared to their properties. There are a lot of advantages to wood pallets but also some disadvantages.

Wooden pallets dimensions
There are several dimensions available to wooden pallets. The most common one in the United States is about 48'' x 40'' x 5'' (1016mm x 1219mm x 120mm).
In Europe they usually use 47.24'' x 32.50'' x 5.00'' (800mm x 1200mm x 120mm). That standard is called EUR- or EU pallets.

But as mentioned above: there are several dimensions of wooden pallets several hundreds actually. If you want more information about standards used internationally you should read ISO 6870 that’s defining 6 dimensions.

Recycling wooden pallets
Damaged wooden pallets are often reconditioned using materials from other wooden pallets. Those wooden pallets that can't be repaired are often turned into wood chips that can be used as animal bedding, playground mulch or burned as wooden pellets.

Buying wooden pallets
There are a couple of things to think about when you want to buy woodenpallets. If you only need a couple of pallets you may want to take a look on the "used pallet" market. Read more about that here.

If you want to buy a large amount of wooden pallets or if you want some special dimensions you're probably better of invite tenders from different companies.

If the wooden pallets should be used to transport goods internationally you have to specify that as those pallets has to be treated against invasive species of insects and plant diseases.


Wooden pallets advantages:
* Wooden pallets are cheap compared to plastic and metal pallets.
* Wooden pallets are recyclable and made from renewable resources.
* Wooden pallets have high friction compared to plastic and metal pallets.
* Wooden pallets are very strong and stiff in relation to their cost.
* Wooden pallets can easily be repaired if damaged.

Wooden pallets disadvantages:
* Wooden pallets can contain invasive species of insects and plant diseases and have to be treated in order to be shipped internationally.
* Wooden pallets can get moldy if they are exposed to moisture.
* Wooden pallets can be hard to keep clean.* Wooden pallets can contain splinters


Conclusion
Wooden pallets are very cost effective and are probably a good choice in most cases. You should look at alternatives when you are looking for a specific property like low weight or cleanliness


However, there are also some reasons as to why plastic pallets are better than wooden pallets:
Advantages of using plastic pallets:
1) Can be nested to gain volume units in small shipping space.
2) Extremely tough and durable for reuse many times.
3) Have a much longer service life than wooden pallets.
4) Are exceptionally light (18-20 Lbs).
5) Generates lower shipping cost (1200 per 40 feet container).
6) Ecology friendly as they are made of recyclable material.
7) Creates a safer work environment, no nails or broken pieces.
8) Can withstand severe temperatures (until 20 grades under zero).
9) Resistant to water, acids and other chemicals.
10) Impervious to insects, nematodes and diseases.
11) Under no export /import regulations.
12) Less expensive with the arrival of new technologies.
13) Requires less plastic wrap to stabilize product on pallet.
14) There is a cost for getting rid of wooden pallets once they are damaged.