Plastic Pallets
High-performance, hygienic plastic pallets engineered for the most demanding environments. 200+ trip lifecycles, zero maintenance, full chemical resistance, and 100% recyclability make plastic pallets the smart long-term investment for pharmaceutical, food, export, and automated supply chains.
Why Choose Plastic Pallets?
Plastic pallets deliver advantages that wood simply cannot match. From zero-maintenance lifecycles to complete hygiene control, here are the reasons our customers switch to plastic.
No Splinters or Nails
Molded as a single piece with zero fasteners. Eliminates the #1 source of worker hand injuries and product damage from protruding nails. Safer for workers, safer for products.
No Fumigation Needed
Plastic is fully exempt from ISPM 15. No heat treatment, no fumigation, no wheat stamp, no customs delays. Ship internationally without phytosanitary compliance costs or risk.
30-50% Lighter
A plastic 48x40 pallet weighs 15-45 lbs vs 45-70 lbs for wood. Less weight means lower freight costs, reduced fuel consumption, easier manual handling, and fewer lifting injuries.
Washable & Hygienic
Non-porous surfaces prevent bacterial growth, moisture absorption, and odor retention. Pressure wash, steam clean, or chemically sanitize without degradation. Essential for food and pharma.
200+ Trip Lifespan
In controlled supply chains, a single plastic pallet replaces 10-15 wood pallets over its lifetime. No boards to crack, no nails to back out, no moisture to cause rot or mold.
Consistent Dimensions
Every plastic pallet is identical to the last. No warping, no shrinking, no swelling. Critical for automated conveyor systems, robotic palletizers, and AS/RS where millimeters matter.
Chemical Resistant
HDPE and PP resist most acids, bases, solvents, and cleaning chemicals. Non-absorbent surfaces prevent contamination. Ideal for chemical processing, pharmaceutical, and hazmat applications.
100% Recyclable
At end of life, plastic pallets are ground and re-molded into new pallets or products. Zero waste to landfill. The recycled material retains most original properties for true closed-loop recycling.
Types of Plastic Pallets
We offer five distinct plastic pallet designs, each optimized for specific storage, handling, and logistics requirements. Choosing the right type is critical to maximizing your ROI.
Nestable Pallets
Designed with tapered legs that nest inside each other when empty, reducing return-freight costs and empty storage space by up to 70%. The nine-leg design is the most common, providing good load support while allowing deep nesting. Nestable pallets are the top choice for export shipping where pallets are not returned, one-way supply chains, and any operation where empty pallet storage space is at a premium.
2,000-3,000 lbs
8,000-15,000 lbs
12-25 lbs
Stackable Pallets
Feature a flat bottom deck that provides a stable surface for stacking loaded pallets on top of each other. When empty, they can be stacked deck-to-deck for efficient storage. Stackable pallets deliver excellent load distribution and work seamlessly with automated conveyor systems, ASRS (Automated Storage and Retrieval Systems), and robotic palletizers. The flat bottom also prevents product damage to items on pallets stacked below.
2,500-5,000 lbs
15,000-30,000 lbs
30-55 lbs
Rackable Pallets
Engineered with reinforced internal structures -- typically steel bar inserts, fiberglass rods, or heavy-duty plastic ribs -- to withstand the demanding loads of beam racking systems. When placed in racks, the pallet is supported only at its two outer edges (the beams), creating maximum stress at the center span. Rackable pallets are designed to resist this deflection while carrying full rated loads over extended periods.
3,000-5,000 lbs
20,000-30,000 lbs
40-65 lbs
Export Pallets
Lightweight plastic pallets specifically designed for international shipping. Because plastic is exempt from ISPM 15 phytosanitary regulations, export plastic pallets do not require heat treatment, fumigation, or any documentation for customs clearance. This eliminates the cost, delay, and compliance risk associated with wood pallets in international trade. Most export plastic pallets are nestable for economical return logistics.
2,000-2,500 lbs
8,000-12,000 lbs
10-18 lbs
Hygienic / Cleanroom Pallets
Premium closed-deck plastic pallets manufactured from FDA-compliant virgin resins in controlled cleanroom environments. The fully sealed top deck eliminates all crevices, holes, and joints where bacteria, mold, or contaminants could harbor. These pallets can be pressure-washed, steam-cleaned, chemically sanitized, or autoclaved without degradation. They meet the strictest requirements of pharmaceutical GMP, food HACCP, and ISO cleanroom classifications.
2,500-4,000 lbs
15,000-25,000 lbs
35-55 lbs
Material Options
We offer plastic pallets in three material options: virgin HDPE, virgin PP, and recycled HDPE. Each material has distinct properties that make it optimal for specific applications.
High-Density Polyethylene (HDPE)
The workhorse of the plastic pallet industry. HDPE accounts for approximately 60% of all plastic pallets manufactured globally. It offers the best all-around balance of impact resistance, chemical resistance, and cost. HDPE excels at low temperatures (down to -40 degrees F) without becoming brittle, making it the material of choice for cold chain and frozen food logistics.
Key Advantages
Technical Properties
Polypropylene (PP)
Polypropylene offers higher stiffness and superior heat resistance compared to HDPE, making it the preferred material for applications requiring autoclave sterilization, high-temperature environments, or maximum rigidity. PP pallets are slightly lighter than HDPE equivalents and exhibit excellent fatigue resistance, meaning they maintain performance over thousands of loading cycles without weakening.
Key Advantages
Technical Properties
Recycled HDPE (rHDPE)
Recycled HDPE pallets are manufactured from post-consumer and post-industrial waste streams, including milk jugs, detergent bottles, industrial drums, and end-of-life plastic pallets. Our recycled-content pallets contain 80-100% recycled material and deliver comparable performance to virgin HDPE in most applications. Choosing recycled plastic diverts thousands of tons of waste from landfills while reducing demand for petroleum-based virgin resin.
Key Advantages
Technical Properties
Wood vs Plastic: Complete Comparison
A comprehensive side-by-side comparison covering every factor that matters when choosing between wood and plastic pallets for your operation.
| Feature | Wood Pallets | Plastic Pallets |
|---|---|---|
| Lifespan | 15-20 trips (new) | 200+ trips |
| Weight (48x40) | 45-70 lbs | 15-55 lbs |
| Hygiene | Porous -- absorbs moisture, bacteria, odors | Non-porous -- easy to wash and sanitize |
| Splinters / Nails | Risk of splinters and protruding nails | No splinters, no fasteners, no dust |
| Maintenance | Requires board replacement and repairs | Zero maintenance over entire lifespan |
| Initial Unit Cost | $5-$25 | $25-$100+ |
| Cost Per Trip | $0.50-$1.50 | $0.12-$0.50 |
| Total Cost (10 years) | Higher (need 10-15 replacements) | Lower (1 pallet lasts the decade) |
| ISPM 15 / Export | Requires heat treatment + stamp | Exempt -- no treatment needed |
| Weather Resistance | Susceptible to rot, warp, mold | Fully resistant -- rain, sun, cold |
| Consistency | Varies in weight and dimensions | Uniform weight and dimensions every unit |
| Recyclability | To mulch, biomass, animal bedding | To new pallets and plastic products |
| Customization | Easy to modify and repair | Requires new mold ($15K-$100K+) |
| Automation Compatible | Dimension variance can cause jams | Consistent -- ideal for automated lines |
Solutions by Industry
Each industry has unique requirements for pallet performance, compliance, and hygiene. Here is how our plastic pallets meet the specific demands of the sectors we serve.
Pharmaceutical & Biotech
Cleanroom-rated plastic pallets manufactured from virgin PP or HDPE in controlled environments. Autoclavable (PP) for sterilization. Fully sealed decks prevent harboring of particulates. Compatible with ISO Class 5-8 cleanrooms. Full lot traceability and certificates of compliance available.
- Autoclavable to 275F
- ISO cleanroom compatible
- Full lot traceability
- Certificate of compliance included
Food & Beverage
FDA food-contact compliant HDPE pallets that resist bacterial growth, moisture absorption, and odor transfer. Non-porous surfaces prevent cross-contamination. Safe for cold chain (-40F), wet environments, and hot-wash sanitation. Available in NSF-certified and HACCP-compatible configurations.
- FDA food-contact approved
- Cold chain rated to -40F
- Hot-washable
- NSF certified options
Chemical & Hazmat
Chemical-resistant HDPE pallets that withstand exposure to acids, bases, solvents, and corrosive materials. Non-absorbent surfaces prevent contamination and simplify hazmat spill cleanup. Spill-containment deck options capture leaks. Available with chemical resistance test data for specific compounds.
- Resistant to most chemicals
- Non-absorbent -- no contamination
- Spill containment deck option
- Chemical resistance data available
Electronics & Semiconductor
Static-dissipative (ESD) plastic pallets that protect sensitive electronic components from electrostatic discharge. Carbon-filled or conductive-additive resins dissipate static charges safely. Particle-free construction meets cleanroom requirements. RFID integration available for automated inventory tracking.
- Static-dissipative (10^5-10^9 ohms)
- Particle-free construction
- Cleanroom compatible
- RFID integration available
Automotive & Manufacturing
Durable, consistent-dimension plastic pallets that integrate seamlessly with automated manufacturing lines, robotic palletizers, and AGV (Automated Guided Vehicle) systems. Dimensional consistency is critical for automation -- plastic pallets maintain exact dimensions over their entire lifespan. Returnable pallet programs reduce long-term cost per trip.
- Exact dimensional consistency
- AGV and robot compatible
- Returnable pallet programs
- Heavy-duty racking rated
Export & International Trade
Lightweight nestable plastic pallets that are completely exempt from ISPM 15 phytosanitary regulations. No heat treatment, no fumigation, no wheat stamp, no customs inspections for wood pest compliance. This eliminates a major source of cost, delay, and compliance risk in international shipping.
- 100% ISPM 15 exempt
- No customs delays for phytosanitary
- Lightweight for lower freight costs
- Consistent tare weight globally
Color Coding for Inventory Management
Color-coded plastic pallets enable visual inventory management, zone identification, and process control without labels or markings. Assign colors to product lines, facilities, quality zones, or supply chain stages for instant identification at a glance.
Black
General purpose, standard, automotive
Blue
Pharmaceutical, cleanroom, food-grade
Red
Quarantine, reject, hazmat, defective goods
Green
Organic products, recycled content, eco programs
Yellow
Caution areas, temporary staging, export
White
Cleanroom, pharmaceutical, high-visibility
Gray
Standard industrial, recycled content
Orange
Return-to-sender programs, rental pools
RFID & Barcode Integration
Transform your plastic pallets into smart tracking devices. Our RFID and barcode integration options enable automated inventory management, real-time location tracking, and complete supply chain visibility from manufacturer to end customer.
Embedded UHF RFID
Passive UHF RFID tags molded directly into the pallet structure during manufacturing. Read range up to 30 feet. Survives washing, impact, and temperature extremes. GS1 EPC standard compliant.
Surface-Mounted RFID
Adhesive-backed RFID tags applied post-production. Easier to add to existing pallets but less durable than embedded options. Replaceable if damaged.
Hot-Stamped Barcodes
Permanent barcodes burned into the pallet surface. Withstand washing, chemicals, and UV exposure. Cannot be peeled off or accidentally removed.
Temperature Sensor Tags
Semi-active RFID tags with integrated temperature sensors for cold chain monitoring. Record min/max temperatures throughout transit. Data downloadable via RFID reader.
Total Cost of Ownership (100 pallets / 10 years)
* Based on 200 trips/year for 10 years. Wood replacement every 20 trips. Prices illustrative -- contact us for actual quotes.
Anti-Slip & Fire Retardant Options
Anti-Slip Surface
Textured or rubber-inlay top deck surfaces that increase friction coefficient by 30-50%. Prevents boxes from sliding during transport, reducing the need for stretch wrap and improving load stability.
Fire Retardant (FM Approved)
Flame-retardant additives meet FM Global, UL, or EN standards. Self-extinguishing pallets reduce fire spread risk. Required by many warehouse insurance policies and automated high-bay storage facilities.
Temperature Range
HDPE: -40F to 180F. PP: -10F to 230F (autoclave to 275F). All load ratings apply at standard conditions (73F). Contact us for temperature-adjusted capacity data.
Cleaning & Sanitation Protocols
One of the greatest advantages of plastic pallets is their ability to be thoroughly cleaned and sanitized. Here are the approved methods for maintaining hygiene standards.
Pressure Washing
Standard garden hose or industrial pressure washer. Effective for removing surface dirt, debris, and light contamination. Most common cleaning method for general-purpose pallets.
Hot Water / Steam
Steam cleaning kills 99.9% of bacteria and is required in many food processing environments. PP pallets can withstand autoclave-level steam sterilization.
Chemical Sanitizing
Compatible with quaternary ammonium, sodium hypochlorite (bleach), peracetic acid, and most commercial sanitizers. Always verify chemical compatibility with pallet material.
UV Sterilization
UV-C germicidal irradiation is effective for surface sterilization without chemicals or heat. Increasingly used in pharmaceutical and food facilities as a supplemental sanitation step.
Environmental Profile
While plastic pallets are made from petroleum-based materials, their environmental profile is more nuanced than it appears. The extended lifespan, zero maintenance, lighter weight, and full recyclability often result in a lower total environmental impact over the pallet lifecycle compared to wood pallets that are frequently replaced.
100% Recyclable at End of Life
Plastic pallets are ground into granulate and re-molded into new pallets or other plastic products. Nothing goes to landfill. We operate a take-back program for end-of-life pallets.
Up to 100% Recycled Content
Many of our pallets are manufactured with 80-100% post-consumer recycled HDPE, diverting thousands of tons of plastic waste from landfills while delivering comparable performance.
Longer Life = Lower Total Impact
One plastic pallet replacing 10-15 wood pallets means fewer trees harvested, fewer pallets manufactured, fewer pallets transported, and less waste generated over the same period.
Lighter Weight = Lower Emissions
At 30-50% lighter than wood, plastic pallets reduce fuel consumption and CO2 emissions for every truck load, every mile, over the entire fleet.
No Chemical Treatments
Plastic pallets never require fumigation, chemical preservatives, or pest treatments -- chemicals that can contaminate products and the environment.
Environmental Facts at a Glance
Frequently Asked Questions
Answers to the most common questions about our plastic pallets. Need more information? Our specialists are always available to help.
How long do plastic pallets actually last compared to wood?
In controlled closed-loop supply chains (warehouse to warehouse), plastic pallets routinely achieve 200+ trips over a 10+ year lifespan. Some customers report pallets lasting 15 years and 500+ trips in gentle-handling environments. By comparison, a new wood pallet averages 15-20 trips before needing repair or replacement. The difference is especially dramatic in environments with moisture, chemicals, or rough handling that accelerate wood deterioration.
Are plastic pallets really exempt from ISPM 15 for international shipping?
Yes. ISPM 15 regulations apply only to solid wood packaging materials. Plastic, metal, and processed wood products (plywood, particle board, oriented strand board) are fully exempt. This means no heat treatment, no fumigation, no wheat stamp, and no phytosanitary inspection at customs. For companies shipping internationally, this eliminates a significant source of cost, delay, and compliance risk.
Can plastic pallets be used in food and pharmaceutical applications?
Absolutely. Our FDA-compliant HDPE and PP pallets are approved for direct food contact under 21 CFR 177. For pharmaceutical applications, we offer GMP-compatible pallets manufactured from virgin resin in controlled environments, with full lot traceability and certificates of compliance. PP pallets can be autoclaved at 275F for sterilization. Hygienic closed-deck models eliminate all crevices where bacteria could harbor.
What temperature range can plastic pallets withstand?
HDPE pallets operate reliably from -40F to 180F (-40C to 82C), making them ideal for cold chain, frozen storage, and outdoor applications. PP pallets handle -10F to 230F (-23C to 110C), with autoclave capability to 275F for short-duration sterilization cycles. Both materials maintain structural integrity across their rated temperature range. Note that load capacity may be reduced at temperature extremes -- contact us for specific ratings.
What chemicals are plastic pallets resistant to?
HDPE pallets are resistant to most acids (sulfuric, hydrochloric, nitric), bases (sodium hydroxide, potassium hydroxide), alcohols, many solvents, and salt solutions. PP pallets share similar resistance but may swell in contact with certain organic solvents (toluene, xylene). Both are unaffected by water, detergents, and common sanitizing agents. We can provide specific chemical resistance data for your compounds on request.
Can you add RFID tags or barcodes to plastic pallets?
Yes. We offer several integration options: embedded RFID tags (UHF, HF, or NFC) molded into the pallet structure during manufacturing, surface-mounted RFID tags attached post-production, hot-stamped permanent barcodes, and applied barcode labels. RFID-enabled pallets allow automated inventory management, real-time location tracking, and temperature monitoring (with sensor tags). We support GS1 EPC standards.
Are there fire-retardant plastic pallet options?
Yes. We offer plastic pallets manufactured with flame-retardant additives that meet FM Global, UL, or European fire classifications. Fire-retardant pallets self-extinguish when the ignition source is removed and significantly reduce flame spread rates. These are required in certain warehouse insurance policies, automated storage facilities, and industries storing flammable goods. Fire-retardant options are available in all pallet types.
What happens to plastic pallets at end of life?
Plastic pallets are 100% recyclable. At end of life, they are ground into granulate and re-molded into new pallets or other plastic products. The recycled material retains most of its original properties, enabling true closed-loop recycling. We operate a take-back program for end-of-life pallets -- contact us for details. Unlike wood, which may end up as low-value mulch, recycled plastic becomes a high-value feedstock.
Get a Quote on Plastic Pallets
Tell us your application, industry, and quantity requirements. We will recommend the optimal plastic pallet type and provide a competitive quote within 24 hours.