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6 Benefits of Using Plastic Pallets in Colors

2/14/2019

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​You've probably noticed most plastic pallets are black. Why? That's easy. They cost less to manufacture. 

And, yes, that means blue plastic pallets cost more. So do plastic pallets made in red, green, yellow or any other color in the rainbow. (Find out why in my next post on the five most popular colors for plastic pallets.) For now, let's look at the many benefits of buying plastic pallets in a specific color and why it's sometimes worth it to spend more.
Custom Color Plastic Pallets
Buying plastic pallets in standard or custom colors can deliver savings in unexpected ways.
6 Benefits of Using Plastic Pallets in Color

They're more than just a prettier pallet, color can help a company:
  
  1. Improve Workflow Efficiency
    Manufacturers and distribution channels boost productivity when color is used to assign pallets by plant function or material.
      
  2. Simplify Inventory Audits
    Managers can get a quick count of inventory just by eyesight. Designated pallet colors are easy to spot whether on the floor or at the top of a pallet rack.

  3. Reduce Risk
    For some companies, cross-contamination is strictly prohibited. Color helps handlers to visually identify the "right" pallet for each material or product.

  4. Meet Regulations
    Need an FM-approved pallet to reduce fire risk? How about one for FDA or USDA safe handling? Pigmentation choices may come into play for approval or simply to make identification easier.

  5. Cut Down on Loss
    Pallet theft is real. Many companies (including the US Postal Service) use color to mark pallets and make them less attractive to pallet poachers.

  6. Grow Brand Recognization
    The most recognized brands rely on color to differentiate themselves from competitors. Custom color pallets offer another option for building brand identity.
      
​Choosing Your Pallet Colors

Many plastic pallet manufacturers offer standard colors or can mix custom colors to match your brand. You should give some thought to your application before choosing a color. Some colors resist fading better than others. Some colors are better recognized in certain applications or could be confused with a competitor. Some colors are just better priced than others. A pallet professional can help you select the best color for your environment and needs.

What color pallet is right for you? Ask us in the comments below or share your own list of benefits for using pallets in designated colors.

Post by: Mike Cunneen, Director of Sales & Marketing
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7 Reasons More Companies are Choosing Used Plastic Pallets

1/10/2019

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​The market for used plastic pallets is strong and for good reason. Reusability.

Plastic pallets are generally engineered for durability. Even the ones manufactured for one-way shipping can often survive multiple trips. The staying power of plastic has increased circulation numbers and introduced an interesting opportunity.
used plastic pallets at Nelson Company
Minor cosmetic damage is OK as long as it does not impact the functionality or integrity of a used plastic pallet.
Sell or Buy Used Pallets

When one company finishes with a plastic pallet, another is ready to put it to use. That means the used pallet market makes it easy for companies to either make or save money.

Here is why more companies are choosing used plastic pallets:
  
  1. A Better Pallet at a Lower Price
    Instead of buying a brand new "low-end" pallet, companies can get a higher-quality pallet in used condition for better reliability and performance.
      
  2. Meets LTL Requirements
    When a truckload is too many, companies can buy just a stack or two of used plastic pallets for one-time or low-volume applications.
      
  3. Supports Sustainability Efforts
    The cost savings and environmental benefits of buying a multi-trip used plastic pallet fit hand-in-hand with sustainability programs.
      
  4. Resale Value
    If requirements change or if a supply chain partner sends in pallets that are not compatible, stacks of unwanted plastic pallets can often be sold for cash.
      
  5. Virtually Maintenance-Free
    Plastic resists mold and bacteria growth. A reliable broker will inspect used plastic pallets for damage and wash them before offering them for sale.
      
  6. Avoids ISPM-15 Regulations
    Even if a plastic pallet has made a roundtrip from the US to Asia and back, it can still be exported again without the risk of costly border holdups.
      
  7. Price Stability
    While fluctuations in resin availability can impact new pallet prices, the used plastic market is typically immune to increases in raw material costs.
      
Used Plastic Pallets are not for Everyone

Companies that choose used plastic pallets must have flexibility. A top reason is that there are few guarantees when it comes to availability. Sources can dry up. Some pallets that enter the used market may be a one-time only opportunity. Plus, loads of the same used pallet can differ in appearance (including variations in design or color).

Are used plastic pallets right for your company? Ask us. We also want to hear which reasons are most important to your pallet buying decision in the comments below.

Post by: Mike Cunneen, Director of Sales & Marketing
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Industry Standard Pallet Sizes: A Complete List

10/29/2018

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The most popular standard pallet size in US inches is 48L x 40W. How popular? The 48x40 accounts for approximately 30% of all wooden pallets produced each year.

The 48x40 standard was set by the Grocery Manufacturers Association (GMA) more than forty years ago. For this reason, you may hear it called a GMA pallet. But, not all 48x40 pallets are designed to GMA specs nor are they all used in the grocery industry. Interestingly, that's true of most any "industry standard" pallet. Even though a pallet may have originally been standardized for a specific trade, its use is often not exclusive to that industry alone.
stacks of wooden pallets
Wooden pallet sizes are expressed in order of stringer length x deckboard length. For example, GMA pallets are 48x40 (not 40x48). Sizes for non-wood pallets are usually listed by the longest length first.
Most Popular US Pallet Sizes

You'll notice many of the most popular sizes on this list are square pallets or nearly square. That's simply physics. A square base can help to prevent load tipping. Below are ways you'll most often see these popular pallet sizes used:
  
  • 48x40 in  Grocery and general warehouse
  • 42x42 in  Telecom; technical coatings and paint
  • 48x48 in  Fits four 55 gallon drums without overhang
  • 40x48 in  Military; cement bags and blocks
  • 48x42 in  Packaged chemicals and beverages
  • 40x40 in  Dairy, designed to fit stacked milk crates
  • 48x45 in  Automotive, meets AIAG specs
  • 44x44 in  Chemical drums and FIBC bulk bags
  • 36x36 in  Beverage, specifically Coke and Pepsi trucks
  • 48x36 in  Roofing and shingles; paper; beverage

    
Pallet Sizes for Exporting


The 1200x800 Euro pallet (you may see it labeled as EUR, EUR1 or EPAL) is Europe's market leader by a landslide. Many European conveyor systems and other handling equipment cannot accept larger pallets. Ship in the wrong size and you may get hit with disposal and repacking fees. Many metric dimension pallets in use around Europe, Asia and other foreign locations are similar in dimensions to popular US pallets bringing us close to global pallet size standardization:
  
  • 1200x800   mm (US 48x32) Most popular; designed to fit European trucks and machinery
  • 1200x1000 mm (US 48x40) Computer warehouses and distribution centers
  • 1140x1140  mm (US 45x45) Maximizes freight density for shipping containers 
  • 1100x1100  mm (US 43x43) Granular chemicals in bulk bags
  • 1190x1135  mm (US 47x45) Export alternative to US automotive standard​

plastic beverage pallet
Beverage pallets like this one perfectly fit 4-case stacks of canned sodas.
Retail and Beverage Pallets

Most anything you drink from an aluminum can, plastic or glass bottle was probably sitting on a beverage pallet (including the popular 36x36 pallet listed above). At the store, you may find your favorite soda pop stacked on a point-of-purchase or retail pallet placed up front or at the end of an aisle. The brewing industry transports beer kegs on larger bulk beverage pallets.

  • 32x24 in  Known as a Half Euro measuring 800x600 mm
  • 36x48 in  Used during manufacturing and warehousing of consumer beverages
  • 37x32 in  Popular with beer distributors because the 32" side easily fits delivery trucks
  • 37x37 in  This beverage pallet holds aluminum cans, plastic and glass bottles
  • 40x24 in  This retail pallet is a great fit for end-cap displays
  • 40x32 in  Big breweries like the 32" side for getting through commercial delivery doors 
  • 48x20 in  This half pallet is half the width of a US standard 48x40
  • 55x43 in  Used for for shipping beverages overseas
  • 56x44 in  Bulk beverage or bulk can pallet for transporting liquids​

plastic drum pallet
CP pallets are manufactured from wood but plastic chemical pallets are also common. The wooden CP3 pallets shown here are designed to be used with drums, bulk bags and octabins.
Chemical Pallets

You will often hear chemical pallets called by the short-cut name, CP pallets. There are nine standard designs manufactured in metric dimensions. Each pallet is stamped with a designation from CP-1 thru CP-9. The specifications were set by European chemical industries but are suitable for many other uses. In the US, chemicals are commonly moved and stored in drums and bags using the popular 48x48 and 44x44 pallets mentioned in the first list.  

  • CP1 1000x1200 mm  Sacks, cardboard boxes, cans
  • CP2   800x1200 mm  Cardboard boxes, drums, cans
  • CP3 1140x1140 mm  Drums, FIBC, octabins
  • CP4 1100x1300 mm  Sacks
  • CP5   780x1140 mm  Cardboard boxes
  • CP6 1200x1000 mm  Sacks
  • CP7 1300x1100 mm  Sacks
  • CP8 1140x1140 mm  Octabins with bottom discharge
  • CP9 1140x1140 mm  Drums, FIBC, octabins

custom wooden pallet
Despite the popular use of industry standard pallet sizes, there are almost as many custom wooden pallets in circulation.
Other Pallet Sizes

The pallet sizes shown in the "most popular" list above make up about 60% of the US market. Every other size in this post plus hundreds of others make up the remaining 40%. The rare standards and a large number of custom wooden pallets in circulation show us that close to half of pallets in use are not a standard size. Some of these include:

  • 1200x1100 mm (US 48x44) Paper industry for supporting heavy paper spools
  • 1100x900   mm (US 43x36) Export

Were any standard pallet sizes from your industry missed? Let me know in the comments below and I'll update the pallet list to make it as complete as possible.

Post by: Jonathan Haynes, Regional Sales Manager
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When do I Need True Freezer Grade Plastic Pallets?

7/12/2018

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OK, so you run a cold storage operation and the FDA has been in a time or two talking about the FSMA and other interesting subjects. So far you are in full compliance, but you thought it might not be a bad idea to look into switching to plastic pallets for your sub-freezing storage. 
Plastic Freezer Pallet
Any operation with consistent temperatures below 0°F should consider using true freezer grade pallets.
Where Do I Even Begin?

No reason to panic. The truth is that MOST plastic pallets available on the market today can withstand temperatures below 32°F without any difficulty. You are at minus 30°F? Holy Cow - that is cold! And, yes, you WILL need a true freezer grade pallet.

So what makes a pallet truly freezer grade? Captain Obvious will tell you, the one that works well in a freezer. One that has the stiffness to do its job as a pallet but one that does not get brittle in cold temperatures. Dah. 

Here are the two main factors that will impact performance in the freezer:
  1. Material
    Simply put, some plastic resins do better in the cold than others. More on that in a bit.
      
  2. Wall Thickness
    Some of the foibles of polypropylene (PP) and other less cold-resistant resins can be overcome simply by making the parts thicker. A PP part at 3/8" thick will be less likely to fail in the cold than say one at 1/8" thick.

Tell Me More About Plastic Resins for Freezer Use

As I mentioned above, brittleness must be considered in material choice. Here's some good info to have:
  • LDPE and HDPE
    Both do well in the cold. Not unusual to see brittle thresholds of -50
    °F for some grades.
     
  • PP and PVC
    These can become brittle even at moderately cold temperatures. Many generic PP grades will get brittle at around 32
    °F. 
     
  • Polystyrene
    This gets brittle if you give it the cold shoulder.
     
  • Structural Foam
    Any resin that has been foamed (as in structural foam) will also become more brittle in the cold than a part molded of the same material but not foamed. 

What About Recycled Material?

Good question. Most applications can be adapted to pallets made from recycled plastic material. When it comes to freezer grade, however, material engineers need to be consulted.

The same material that does well as a virgin, unblended resin will lose physical properties each time it is recycled. To combat this, the better engineered pallets will add an elastomer filled resin like TPO to the mix. In layman’s terms, this is like adding rubber to the plastic. The chemistry behind all of this can be like voodoo and is often a well-guarded secret. For us, it means the pallets will still be stiff enough to do their jobs, but will not get brittle when they are cold.


I Think I Need a True Freezer Pallet. Now What?

​To recap, if your work environment is really cold, say lower than 0°F, you should consider a true freezer grade pallet when buying plastic. If you intend to use a pallet molded from virgin material, ask specific questions about the material from which that pallet is molded. Working temperature ranges are listed for all plastic resins, and your supplier should have that data in writing. If you are considering pallets with recycled content, look for a supplier that offers an engineered solution, specifically addressing your low temperature needs.

Still confused? Best to reach out to a pallet professional or you can post your questions here.
​
Post by: Hartson Poland, Business Development - Plastic
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Shipping Air Freight? Optimize Cost with the Right Plastic Pallet

5/10/2018

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Air freight is the creme de la creme of all shipping methods and comes with a hefty price tag. But, can choosing the right pallet for air shipments really help "lighten the load"? Yes. Yes it can.
Air freight shipping
Lightweight and nestable plastic pallets save on air freight. Optional snap-on runners add secure stacking capabilities.
Choose the Right Air Freight Pallet

Air freight can be expensive. But cost-conscious businesses with lean inventory often depend on air freight (instead of ocean) to move product in a timely, more predictable manner. So how can these businesses optimize air freight cost? Easy. Consider these money-saving air freight tips:
  
  • Follow Industry Standards
    By industry standards, I mean shipping on an ISPM-15 exempt pallet. All plastic pallets are inherently compliant with export regulations so they eliminate the need for stamping and documentation. This makes exporting hassle-free and lessens the chance for freight delays.

  • Go Light
    You know how you get charged for that extra suitcase when you fly on a trip? Well, that's what airlines call chargeable weight and it applies to cargo too. It is calculated using weight and dimensions. The lightweight nature of plastic pallets makes most of them export friendly. So choosing a 15 lb plastic pallet over a 35-40 lb pallet is really going to save you some money.

  • Think Nestable
    Nestable pallets tend to be lighter in weight and cost less. This is especially important to consider when the pallets are shipping one-way and are not expected to return. When not in use, nestable pallets take up less space to save money in storage and transport costs. 

  • Add Optional Runners
    Need more support? Some loads require more secure stacking capabilities when shipping via air cargo. A popular option for creating a flat and safe surface is to snap on runners to the bottom of nestable pallets. This still keeps the pallet weight and price down but adds stacking and racking capabilities.

  • Get Size Advice
    Size matters. Plastic pallets have consistent and precise sizing and weights to make calculating your loads easier. Not only that, they come in many sizes to work with your application. The right size can prevent cargo damage and save money.

  • Ask About Used
    New isn't always better. There is a huge selection of used plastic pallets that are ideal for export. Used pallets are structurally sound and typically have only some minor cosmetic damage. Best of all, they cost less.
  
Reduce Headaches and Save Money

Shipping air freight can be an expensive headache. Using the wrong pallet for export could be costing more than you realize. Getting expert advice for choosing the right plastic pallet really can help make the process easier and cheaper.

Have a question about choosing the best pallet for your air freight application? Post it here.

Post by Lindsey Silverman, Business Development Representative
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1,800 RACKABLE pallets in ONE Truckload: Fact or Fiction

2/8/2018

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Paying an arm and a leg for pallet freight these days? What if you could get 3 truckloads of rackable pallets delivered for the price of one traditional load?
RackNest Plastic Pallet
Revolutionary design of the RackNest plastic pallet saves space on the truck and on the floor.
Make the Most of your Freight and Floor Space

Traditional rackable pallets only fit about 500 per 53' truck. The same 500 pallets take up valuable space on your warehouse floor as they only stack 17-18 pallets high. The new RackNest plastic pallet fits 1,800 per truckload and 60 pallets per stack.
  • ​Save BIG $$$ on freight
    Say you're paying $1,000 freight for a load of traditional rackable pallets and you can only fit 500 per truck. That's $2.00 freight per pallet. Now consider the RackNest... $1,000 freight / 1,800 per truck = $0.55 per pallet. It would cost you $3,600 to get 1,800 traditional rackable pallets delivered. You just saved $2,600 in freight!
       
  • Fit 3 times as many pallets on the floor
    Instead of having 30 stacks, 16-17 pallets high, with the RackNest you will have 30 stacks, 60 pallets high. That's around 1,300 more pallets in the same space!
      
  • Order less often and always be ready for a spike in production
    We all wish we could have multiple truckloads of rackable pallets on hand just in case production picks up unexpectedly. With the RackNest, when you order one load you'll get 3X more than you currently get. That's plenty for normal usage as well as any surge that may come down the line.

No one likes getting caught in a jam. If you're wondering if you can just wait out rising freight rates and increasing lead times, check out this article on a nationwide shortage of trucks from the Wall Street Journal.
​  
Least Expensive Rackable Plastic Pallet

Stop stressing about high freight bills, tight floor space and quickly dissolving inventory of rackable pallets. The RackNest provides an ergonomic pallet that saves freight cost, space and administration time without compromising strength or functionality. Oh, and did I mention it is one of, if not the least expensive rackable pallet on the market? Yup, we call that the icing on the cake.

Yes, I agree, the RackNest sounds too good to be true. We thought the same thing until we had it tested at the Virginia Tech Center for Unit Load Design. Confirmed... it is the real deal.  Grab a spec sheet to see the RackNest load capacities and unique design for yourself.

Do you think the RackNest could work for you? Leave a comment below (or shoot me an email) and let me know what you think.

Post by: Mike Cunneen, Director of Sales & Marketing
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A Captive Pallet for the Future

10/16/2017

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Plastic lumber offers captive pallets a new future.

Captive pallets are designed to save money by being reusable. Plastic lumber is repairable and durable. Plus, it can be custom made to fit your specific requirements. Sounds pretty good so far. But will it work for you?

Below we explore the benefits and drawbacks to plastic lumber pallets.
Plastic Lumber Pallet
A plastic lumber pallet can provide an alternative to traditional wooden or plastic pallets.​
Comparison to Traditional Wooden and Plastic Pallets

Captive pallets are pallets designed to last in a warehouse environment for repetitive use. Both traditional wooden pallets and plastic pallets are used in these applications.

  • Heavy duty plastic pallets have become popular as a captive pallet in many industries. Unfortunately, they do not fit the needs of all customers because custom sizes and designs can be cost prohibitive.
      
  • Wooden pallets are less expensive to produce and can be repaired when minor damage has occurred. Even though wood is often used for captive pallets, they can be easily damaged, require mold prevention treatment and can’t be easily sanitized.

Is Plastic Lumber Right for You?

The biggest advantage of a plastic lumber captive pallet is custom design. Custom designs are often worth looking at because they can uncover hidden savings.

A design team is critical to the this process. In addition to drafting a new design, the team reviews all supply chain systems to make sure the pallet will work with all material handling equipment. Utilizing a service such as the Nelson Tech Center provides expertise for reducing total cost of ownership and improved sustainability.

Here are some pros and cons to consider:

Benefits of Plastic Lumber Board
  • Durable
  • No moisture problems (reduces mold and decay)
  • Cleanliness
  • Can be nailed using the same equipment as wood pallets

Drawbacks of Plastic Lumber Board
  • Higher initial cost
  • Boards must be nailed or screwed together using metal fasteners
  • Weight (plastic lumber can be heavier than most wood species)
    
Captive pallets have undergone many changes in the last 50 years - especially with the introduction of plastic pallets. While plastic pallets do not fit every need, the introduction of plastic lumber provides a new option for a custom-sized captive pallet.  

In what ways could a captive pallet made from plastic lumber work for you? Share your thoughts in the comments below.

Post by: Jonathan Haynes, Regional Sales Manager
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Rackable Pallets - What About the Load?

7/13/2017

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​What makes a pallet rackable? Well, we've been spending some time on that question including getting into pallet structure, material stiffness and the seven racking systems we most commonly find in industry. 

Part of the discussion included assigned load ratings. In most cases, rackability ratings assume the pallet can safely bridge a span between supporting structures. The ability to dependably and securely bridge that span is what makes a pallet rackable.
Racking Pallet Bridging Span
Metal Pallet Bridging the Span in a Rack
Nature of the Load

A common standard for rackability is 2200 pounds or about one metric ton. But what about that ton? Is a ton of feathers the same as a ton of lead? Well, we know they both weigh the same but their nature is very different. And it is the nature of the load that also needs to be considered when determining the suitability of any pallet for its intended use.
Bale of Cotton
A bale of cotton weighs about 480 pounds.
A Stiff Load can Increase Functional Racking

If we were to make a stack of 40x48 sheets of 3/4 inch plywood on a pallet, it might end up being very heavy. Think about the last time you got an unassembled piece of furniture from IKEA. Holy smokes that stuff can be heavy! But, because our stack is stiff and spreads the load over the entire surface of our pallet, the load actually helps impart stiffness to the pallet. So even though it is very heavy, this type of load increases the functional racking load rather than challenging it!

By contrast, if the load is not in of itself stiff, it can cause a problem. Yep, even if we evenly spread the load across the surface of a pallet. Now what? Well, unitizing a load with stretch wrap can take a challenging load and make it less so. The stretch wrap makes the load stiffer, more like our stack of plywood. But, no matter what, our stack of plywood will always be stiffer than say, small bottles shrink wrapped in bundles and stacked on a pallet.

Challenging Loads

In addition to our example of stacked bottles in stretch wrap, here are some of the more common challenging loads for rackable pallets:
  • 5 gallon pails
  • Steel or poly drums
  • Bulk bags
  • Smaller bags of seeds or beans
  • Any single heavy item placed in the center of the pallet
    see my story below on this one...
Unitized pallet loads in racking system
Pallet loads unitized with stretch wrap and placed in racking system.
Story time... I was once shown a 3,500 lb lift truck counterweight and asked to propose a pallet to handle it. I had a GREAT solution. Of course, the picture in my mind is the weight laying flat on its back and spread out over the surface of the pallet. I sent over a sample pallet and was mortified when I got an email showing the pallet in total failure! What happened? The counterweight was placed upside down with only three 4x4" points of contact on the pallet. Heaven knows what the PSI must have been on those three points, but I can tell you the highly-rated pallet folded like a cheap camera!

Getting it Right the First Time

To recap, the nature of the load must be considered when determining the suitability of a pallet for any given application - especially if it is said to be "rackable".

Load rating will generally assume the loads will be:
  1. Unitized
  2. Distributed evenly over the surface of the pallet

But even then you need to ask yourself the right questions. For example, will we be moving a ton of feathers or a ton of lead? The answers will help you get it right the first time.

If you want help with your load questions, ask a pallet professional or please post them below. And watch for my next post on the history of the unit load and how we got here in the first place.

Post by: Hartson Poland, Business Development - Plastic
Use of metal racking photo used with permission from our friends at Warehouse Rack & Shelf, LLC.
Use of  Forklifts in Warehouse photo by Mdornseif licensed under the Creative Commons Attribution 3.0 Unported license.
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Why is Mold Growing on my Pallet?

4/13/2017

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Your pallets look clean, your production facility is exemplary, yet once you put your product on the pallet and stretch wrap the unit load, mold starts to appear!

​
What's to blame and how can I avoid this from happening?
wood pallet with mold
The perfect storm for mold growth.
The Hunt for Mold

Don't feel bad, people in production facilities all over the world find themselves asking the same questions throughout the year. To find the answer, we'll address 4 variables for the unit load pictured above.
  
  1. The wood pallets appear to be clean but...
    As you know, wood comes from a living thing.  Even if it is treated and appears to be free of dirt and mold, every wooden pallet still has some degree of bacteria and moisture present.
      
  2. What does my product have to do with mold...
    Does your product come off the line warm? If so, it may be using that heat to draw out moisture from the pallet. So, what if the warm bags are on a slip sheet or a piece or corrugate and they aren’t even touching the pallet? See the next point...
      
  3. Wood Pallet + Warm Product + Stretch Wrap = Mold Incubator
    That's right. Warm product combined with a wood pallet that's been sealed tight with stretch wrap can trap the warmth and promote mold growth. Obviously, this can be exacerbated by high summer temperatures (variable #4) which was the case in the picture above.
Well there you have it. It's not one thing causing the mold but instead, it's a combination of 3 or 4 things.

What Happens Now?

In some situations, it may be possible to save your moldy wood pallets. Other times conditions simply don't make for a fair fight. In this particular case (pictured), the facility immediately opted to switch over to plastic pallets to avoid sending mold-damaged product to customers.

Have you experienced similar mold issues on pallets? Tell us what did you do to fix the problem or ask for expert advice in the comments below.
​
Post by: Mike Cunneen, Director of Sales & Marketing
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Racking: Is your pallet material up for the job?

2/9/2017

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​In my last post we talked about how the STRUCTURE of a plastic pallet can impact the way it interfaces with pallet racking. In this discussion, we will address MATERIAL as it relates to the rackability of a plastic pallet. 

For our purposes here, we will assume our pallets need to bridge an open span in a rack. If you haven't been following along in this series, check out my 7 Ways to Use Rackable Pallets post to get up-to-speed.
plastic pallet resin
Commodities plastics used in pallet manufacturing is one consideration when determining native stiffness.
Stiffness Matters

Again, assuming our pallet has the proper structure to target on the rack safely, what is the main pallet characteristic for allowing it to bridge the span without deflecting? STIFFNESS! And yes, this actually is a technical term that can be measured.

Plastic resin producers have ways of testing various plastic materials and coming up with numbers to reflect properties best suited to an application. These plastic materials can vary in:
  • Stiffness
  • Stretchiness
  • Stress resistance 
  • Squishiness 
  • Toughness

Loads can Complicate Things

The bottom line for us is using a material that is stiff enough to bridge our span carrying a load. Load? Did someone mention a load? For our purposes here, we will assume our loads are evenly distributed across the surface of our pallets. The nature of a load can certainly impact the performance of a pallet, but the subject is complex enough that we will leave load configuration for another day.
​
Stiffness can be Achieved in Several Ways

  • Native Stiffness 
    Native stiffness is measured by its (are you ready for this?) flexural modulus of elasticity. In English, this means how the material bends when subjected to force. Some materials are simply stiffer than others depending on their molecular makeup. So we just choose the stiffest possible material available, right? Not so fast! When it comes to pallets, we need to balance stiffness with toughness and impact resistance.
      
    For most commodities plastic, if we get really really stiff we also get brittle and that is bad news to a device that is intended to work in high impact environments. This would be a good time to mention that native stiffness can be affected by temperature. When tested for the properties mentioned above, most labs use 73 degrees F as the ambient temperature during a test. Hotter environments can cause plastic to "creep" increasing defection over time. And let's not forget that stiffness increases as vertical depth increases. For our purposes we will assume pallets with a height of about 6 inches. Deeper would be stiffer, but pallets that are too high steal valuable load space.

  • Loading or Filling
    Plastic material can be fortified with a filler material that will add stiffness and create what is essentially a plastic composite. Some fillers like powdered minerals or cellulose fibers will add stiffness but can also make pallets less impact resistant. Short glass fibers can add stiffness but might be shed if subjected to impact.
Steel rod inserts for plastic pallet
Usually square and made of steel, rod inserts can add stiffness to a plastic pallet for racking.
  • Reinforcement
    ​If a manufacturer has settled on a plastic material that has all of the physical characteristics he desires except stiffness, a pallet can be made stiff by introducing a bar, rod or beam into the structure of the pallet for achieving the stiffness and load rating desired. The most common reinforcement material is steel. These square tubes are placed in either the deck or the bottom frame of the pallet in the direction of the span. In some cases, rods can be placed in both directions making the pallet fully rackable regardless of how it is placed in the rack.
      
    We also find pallets strengthened with fiber reinforced beams. These little I-beams are made of dense thermoset resin reinforced with long fiber glass. As these beams are encased in the structure of the pallet, impact to the beams themselves is rarely an issue.
fiber reinforced insert for plastic racking pallet
Fiber reinforced beams like these are better protected from impact due to being encased in the pallet.

​​In conclusion, it is safe to say that most commodities plastics used to mold plastic pallets today allow a certain degree of rackability with only a well-designed structure and the native stiffness of the plastic. A common target "racking load rating" for a 48x40 full frame plastic pallet is 2200 pounds. Although not universal, this is a common target. Most certainly if higher racking ratings are required, the introduction of either fillers to create a stiffer composite or some form of reinforcement rods would be needed. 

If you still have questions about how material or structure apply to the selection of a rackable plastic pallet, you can post them here. And, be sure to watch for my next post on the unit load itself and how load configuration can impact how a pallet will behave in a rack.

Post by: Hartson Poland, Business Development - Plastic
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