Custom Pallet Solutions Engineered for Your Business
When standard pallets do not fit, we engineer exactly what you need. From custom dimensions and specialty materials to complete pallet management programs and automated handling integration, our solutions team designs and delivers pallet programs built around your exact specifications.
Everything You Need, Engineered to Spec
From single-specification builds to complete pallet management programs, we tailor every aspect of our service to match your unique requirements.
Custom Pallet Design & Engineering
Our engineering team designs pallets from the ground up to match your exact product dimensions, weight requirements, handling methods, and storage configurations. We use CAD software to model each design, analyze load distribution, and optimize material usage before cutting a single board. Whether you need a pallet that fits an unusual product shape, supports extreme weight, or integrates with automated handling equipment, we engineer the solution.
Includes:
- CAD-modeled design with load analysis
- Any dimension up to 72" x 72"
- Custom deck board spacing and thickness
- Variable stringer heights and configurations
- Two-way and four-way entry options
- Notched, flush, or block-style stringers
- Weight optimization for shipping cost reduction
Specialty Materials
Different environments demand different materials. We source and fabricate pallets from a wide range of specialty materials to meet your specific performance, regulatory, and environmental requirements. From kiln-dried hardwood for heavy industrial loads to food-grade plastic for pharmaceutical cleanrooms, we match the material to your application.
Includes:
- Hardwood (oak, maple, ash) for maximum strength
- Softwood (pine, spruce, fir) for lightweight applications
- Kiln-dried lumber for moisture-sensitive environments
- HDPE plastic for cleanroom and washdown areas
- Composite and hybrid materials for specialized needs
- Stainless steel for extreme hygiene requirements
- Presswood for lightweight export shipping
Heat Treatment & Fumigation (ISPM 15)
International shipping regulations require wood packaging materials to be treated against pests. Our certified heat treatment facility processes pallets to ISPM 15 standards, raising core wood temperatures to 56 degrees Celsius for a minimum of 30 minutes. We also provide methyl bromide fumigation where required by specific destination countries, though heat treatment is the preferred and more environmentally responsible option.
Includes:
- ISPM 15 certified heat treatment kiln
- Official IPPC stamp on every treated unit
- Core temperature monitoring and documentation
- Batch certificates for export compliance
- Fast turnaround: 24-48 hours standard
- Rush same-day treatment available
- Fumigation services where required
Stenciling, Branding & Color Coding
Transform your pallets into brand assets and tracking tools. We offer comprehensive marking services including hot-brand company logos, ink stamp markings, color-coded paint systems for departmental routing, barcode and QR code labels for digital tracking, and custom identification numbering for inventory management. Professional pallet marking improves logistics efficiency, reduces misrouting, and presents a polished image to your customers.
Includes:
- Hot-brand logo application
- Industrial ink stamp markings
- Color coding systems by product, route, or department
- Barcode and QR code labels
- RFID tag integration
- Sequential numbering for tracking
- Regulatory compliance markings
Pallet Pooling Programs
Instead of buying and managing your own pallet inventory, our pooling program provides shared-use pallets on a rental basis. You receive clean, inspected pallets when you need them and return them when finished. We handle all maintenance, repair, and logistics. Pallet pooling reduces your capital expenditure, eliminates storage of empty pallets, and ensures consistent quality without the management overhead.
Includes:
- No capital investment in pallet inventory
- Regular delivery of inspected, graded pallets
- Return logistics managed by Pallets Eco
- All maintenance and repairs included
- Flexible volume adjustment month to month
- Per-trip or monthly billing options
- Sustainability benefits: pallets are shared and recycled
Pallet Management & Tracking Systems
Take control of your pallet operations with our comprehensive management and tracking platform. We deploy barcode or RFID tracking on every pallet, provide real-time inventory dashboards, and generate analytics reports that reveal exactly where your pallets are, how many cycles they have completed, and when they need replacement. This data-driven approach eliminates pallet loss, reduces overspending, and optimizes your entire pallet supply chain.
Includes:
- Barcode and RFID tracking systems
- Real-time inventory dashboards
- Pallet lifecycle analytics
- Loss prevention and tracking
- Automated reorder triggers
- Cost-per-trip analysis
- Integration with WMS and ERP systems
Built for Your Industry
Different industries have drastically different pallet requirements. We understand the unique regulations, standards, and operational demands across sectors and engineer solutions that meet them precisely.
Pharmaceutical & Healthcare
GMP-compliant pallet solutions designed for pharmaceutical manufacturing and medical supply distribution. Every pallet meets the strictest contamination controls, provides full batch traceability, and is documented for regulatory audit purposes. We understand FDA 21 CFR requirements and design pallets that protect product integrity throughout the cold chain.
Aerospace & Defense
Engineered pallets for aerospace components and military logistics. We build to MIL-SPEC standards when required, designing pallets that protect high-value, precision-machined parts during domestic and international transport. Custom cradles, shock-absorbing features, and corrosion-resistant materials ensure your components arrive undamaged.
Automotive
Heavy-duty pallets engineered for the unique demands of automotive parts distribution. From engine blocks and transmissions to body panels and small components, we design pallets with the weight capacity, surface protection, and custom configurations the automotive industry requires. Returnable designs reduce per-trip costs.
Food & Beverage (FDA Compliant)
Food-safe pallets meeting FDA, USDA, and FSMA requirements for food processing, cold storage, and distribution. We provide heat-treated, contamination-free pallets suitable for direct food contact environments. All materials are traceable and documented for food safety audit compliance.
Military & Government
Pallets built to government and military specifications for defense logistics, FEMA disaster response, and government agency supply chains. We work with contracting officers and logistics planners to meet specific procurement requirements including Buy American Act compliance.
E-Commerce & Fulfillment
Automation-compatible pallets with precision dimensions for high-speed sortation systems, robotic warehouse operations, and automated storage and retrieval systems (AS/RS). Dimensional consistency within 1/8 inch tolerance ensures flawless performance in automated environments.
Expert Consulting Services
Not sure what you need? Our pallet supply chain consultants analyze your operations and design programs that reduce costs, improve efficiency, and meet sustainability goals.
Supply Chain Optimization
We analyze your entire pallet supply chain from procurement to disposal, identifying inefficiencies, redundancies, and cost-saving opportunities. Our consultants map your pallet flow, benchmark your costs against industry standards, and develop actionable recommendations to reduce spend and improve operational efficiency.
Pallet Spend Analysis
A comprehensive audit of your current pallet expenditures across all categories: purchase, repair, transportation, storage, and disposal. We provide a detailed report showing where your money goes, where you are overpaying, and specific strategies to reduce total pallet costs by 15-40%.
Sustainability Roadmap
Working with your sustainability team, we develop a roadmap for transitioning to more environmentally responsible pallet operations. This includes recycling program design, material sourcing optimization, lifecycle extension strategies, and carbon impact measurement and reporting.
Automation Compatibility Assessment
If you are implementing or upgrading automated warehouse systems, we assess your pallet specifications against automation requirements and recommend designs that ensure compatibility with conveyors, sorters, AS/RS systems, and robotic handling equipment.
From Consultation to Production in 5 Steps
Our custom solutions process is collaborative and transparent. We work with you at every step to ensure the final product is exactly right.
Consultation
We start by listening. Tell us about your products, your handling processes, your storage environment, your compliance requirements, and your budget. We ask detailed questions because the more we understand about your operation, the better the solution we can engineer.
Design & Engineering
Our engineering team creates detailed CAD drawings of your custom pallet, including load distribution analysis, material specifications, and dimensional blueprints. We present the design along with material options, cost projections, and performance specifications for your review.
Prototype
We build physical prototypes of your custom pallet for hands-on evaluation. You can test the prototype in your actual operational environment: load it with your products, run it through your handling equipment, stack it in your racks. Real-world testing before full production commitment.
Testing & Refinement
Based on your prototype feedback, we make any necessary adjustments. We also conduct formal load testing, compression testing, and drop testing to verify the pallet meets or exceeds the performance specifications. Engineering sign-off confirms the design is production-ready.
Production & Delivery
With the design finalized and approved, we begin full-scale production. Our fabrication team builds your custom pallets with consistent quality, applying all specified treatments, markings, and features. Delivery is coordinated on your timeline with ongoing quality monitoring.
Prototyping & Testing Before Production
We never go to full production without your hands-on approval. Every custom design goes through a rigorous prototyping and testing phase where you can evaluate the pallet in your real operational environment.
Export Packaging Solutions
Shipping internationally requires specialized packaging that meets customs regulations, protects goods through multi-modal transport, and maximizes container utilization. Our export packaging team handles everything.
- ISPM 15 heat-treated pallets for all international destinations
- Custom crating and boxing for high-value export goods
- Moisture barrier packaging for ocean freight
- Export documentation and phytosanitary certificates
- Container-optimized pallet dimensions for maximum cube utilization
- VCI (Volatile Corrosion Inhibitor) packaging for metal components
- Shock and vibration protection for sensitive equipment
- Multi-modal packaging designed for truck, rail, ocean, and air transport
Custom Solutions in Action
Precision Aerospace Components
The Challenge: Precision Aerospace was experiencing a 3.5% damage rate on high-value machined titanium components during domestic shipping. Each damaged part cost $15,000-$45,000 to replace, resulting in annual damage costs exceeding $800,000.
The Solution: Pallets Eco designed a custom pallet with shock-absorbing cradles, anti-vibration foam inserts, and precisely machined component wells that held each part securely during transit. The pallet was engineered for their specific automated loading system and included RFID tracking for chain-of-custody documentation.
Columbia Valley Wine Distributors
The Challenge: Columbia Valley needed export-ready pallets for shipping premium wines to 12 countries across Europe and Asia. Their existing pallets did not meet ISPM 15 requirements, and inconsistent sizing caused loading inefficiencies that wasted 15% of container space.
The Solution: We designed a custom heat-treated pallet sized specifically for their wine case dimensions, maximizing container utilization. Each pallet included anti-slip deck surfaces, branded markings, QR code tracking labels, and full ISPM 15 compliance documentation for seamless customs clearance.
Why Invest in Custom Pallets?
Standard pallets are designed for general use, but your business is not general. Custom pallets reduce product damage, improve handling efficiency, optimize container utilization, and can lower your total logistics costs substantially.
When pallets fit your products perfectly, you use less secondary packaging, reduce breakage during transit, move goods faster through your facility, and present a more professional image to your customers. The upfront investment typically pays for itself within 3-6 months.
Average Reduction in Product Damage
Custom-fit pallets eliminate product shifting and reduce impact during transport.
Improvement in Loading Efficiency
Right-sized pallets mean more product per truck and fewer trips to make.
Better Container Utilization
Pallets sized for your containers maximize cubic footage and reduce shipping costs.
Typical ROI Payback Period
Most customers recoup their custom pallet investment within the first half year.
Frequently Asked Questions
What is the minimum order quantity for custom pallets?
Our minimum order for custom pallet production is typically 50 units. For highly specialized designs requiring significant engineering work, we may require a higher minimum to justify the setup costs. However, we are flexible and will work with you to find a practical solution regardless of your volume needs. The per-unit cost decreases significantly with larger orders.
How long does it take from initial consultation to receiving custom pallets?
Our standard timeline from consultation to first delivery is 2-4 weeks, depending on design complexity. Simple modifications to existing designs (size changes, additional boards) can be turned around in 1-2 weeks. Complex engineered designs with prototyping and testing typically take 3-4 weeks. Rush production is available for an additional fee.
Can you match pallets that we are currently sourcing from another provider?
Absolutely. Provide us with samples, drawings, or specifications of your current pallets and we will replicate them exactly or improve upon the design. We frequently help customers transition from existing suppliers and can often offer better pricing, quality, or delivery terms.
Do you provide prototypes before full production?
Yes, prototyping is a standard part of our custom pallet process. We build physical prototypes that you can test in your actual operational environment before committing to full production. There is typically a small charge for prototype production, which is credited toward your first production order.
Can custom pallets be recycled at end of life?
Yes. We design our custom pallets with end-of-life recyclability in mind. When your custom pallets reach the end of their useful life, we take them back through our recycling program and recover the materials. This closes the loop and ensures your custom pallet investment contributes to the circular economy rather than ending up in a landfill.
What about automated pallet handling integration?
We have extensive experience designing pallets for automated systems including conveyors, automated storage and retrieval systems (AS/RS), robotic pallet handling, and high-speed sortation. We can test compatibility with your specific equipment and hold dimensional tolerances as tight as 1/8 inch to ensure flawless automated handling performance.
Ready to Build Something Custom?
No matter how unique your requirements, our custom solutions team has the engineering expertise, manufacturing capability, and industry knowledge to deliver exactly what you need. From a single custom specification to a full pallet management program, we are ready to partner with you.
Every custom project begins with a conversation. There is no obligation, no pressure, and no commitment required for the initial consultation. Tell us what you need, and we will show you what is possible.
Start Your Custom ProjectRequest a Custom Solution Quote
Describe your custom pallet needs in as much detail as possible and our solutions team will reach out within 24 hours with a tailored proposal.