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.

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​

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. 

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.
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Post by: Hartson Poland, Business Development - Plastic

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.

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

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?

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.
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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.

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

​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.

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.

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...

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.

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?

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.
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Post by: Mike Cunneen, Director of Sales & Marketing

​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.

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.
​

​​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

In my last post we discussed 7 basic types of pallet racks. Now that we know EVERYTHING (well, almost everything) there is to know about pallet racking, let's talk about how pallets interact with racks and why structure matters.

When is a Pallet Rackable?

We often hear the term rackable plastic pallet but what does that really mean? Traditionally we think of wood pallets as setting the standard for rackability. Simply stated, any pallet, plastic or wood is rackable when it has the capacity to bridge a span. Remember the span? This is the open space between supports in a rack. Let’s recap:
  

1. Beam Rack
   span is the distance between the front and back beams parallel to the aisle
2. Edge Rack
   span is the distance between rails or edges perpendicular to the aisle
3. Roller Rack
   span is the distance between roller sets, often like the edge rack but may have a center roller set eliminating the span
4. Push Back Rack
   span is determined by the design of the platform
5. Flow Rack
   like a roller rack but with a pitch to move pallets along by gravity
6. Cantilever Rack
   span is determined by the space between perpendicular beams
7. Supported Rack
   no span

So is it that easy? As long as the pallet is rated on the spec sheet for a racking load of say 2,200 pounds and our loads match the weight, we are good to go, right? Not necessarily.

Pallet Design Matters

There are two basic design elements we need to consider:

• Structure
• Material

In this post, we will talk about structure. The underside of the pallet interfaces (score one geek term) with the rack so the bottom structure should be designed to easily target the supporting horizontal structure of the rack:

Full Frame Cruciform Pallet
If we are looking at a simple beam rack with a front and back beam parallel to the aisle, the underside of the pallet should have enough structure to safely target on those beams. A full frame cruciform pallet provides runners in both directions allowing the pallet to be racked in both dimensions. 

Three Runner Pallet
In the case of the three runner pallet, the pallet should only be placed in the rack with the runners perpendicular to the beams. 

Pallets for Edge Racks

A pallet must have a bottom structure that will safely rest on the edge. Pallets with a radius on the runners (or heaven forbid a pallet that just has feet for support) is not suitable. Trying to target these types of pallets on racks with narrow edges would be like wire walking. Works if you're one of The Flying Wallendas, not so much for the average forklift operator. 

Pallets for Roller Racks

Any part of the pallet bottom that interfaces (there I geek again) with the rollers should be smooth enough to flow on the rollers without chattering or bumping along. Why? We don't want vibration to transfer to the load. Many plastic pallets tend to have ribbing in the understructure. In this case, the tighter the ribbing pattern the better. 

Pallets for Push Back Racks

The design of the platform being pushed back determines whether or not a full frame pallet, runner pallet or even a pallet with just legs may be suitable. Some platforms are fully solid while others have a frame like this one pictured below. 

Pallets for Cantilever Racks

Structure matters and the underside of the pallet should have enough length to safely reach from one rack arm to the next. As cantilever racking is often used for longer items like siding or lengths of tubing, pallets would need to be specifically designed to handle those lengthy items in relationship to the racks intended for use.

Now you know the basics of how pallet structure can impact how that pallet will work in the most common racking systems found in industry today. If you still have questions, please post them here.

Note: For the purpose of this post, we assumed that the pallets were stiff enough to safely bridge the span without unacceptable deflection (bending) cracking or breaking. Watch for my next installment on how we make pallets stiff enough to bridge the span in the first place.

Post by: Hartson Poland, Business Development - Plastic
Use of push back and cantilevere racking system photos used with permission from our friends at Warehouse Rack & Shelf, LLC.

Rackable pallets are designed to be used in racking systems - but what does that really mean?

Rackable pallets (plastic or otherwise) are pallets that are expected to bridge an open span. Much like the Brooklyn Bridge suspends high above the rushing waters of the East River, a rackable pallet spans a distance between supports in a rack.

You may be scratching your head right about now so let’s back up a little. Pallet rack? What the heck is a pallet rack? Any conversation about rackable pallets needs to start with the various types of pallet racks found in industry. This post will identify seven of the most common racking systems used with rackable pallets.
​  

1. Beam Rack
This is a typical shelf-like structure with steel uprights and horizontal beams front and back. The pallet sits on the beams. The "span" being bridged is the distance of open space front to back

2. Edge Rack
Typically designed to drive in with a lift truck, this type of rack has rails often made of steel angle iron running perpendicular to the aisle. The pallet sits on the rail and the span being bridged is the distance between the rails. 

3. Roller Rack
These are racks designed with rollers positioned at the pallet’s contact points. These can look just like an edge rack but instead of simple angle iron, the rails are replaced by rollers. The span in this case would be similar to the edge rack.

4. Push-Back Rack
This type of racking system employs an intrinsic platform that is loaded and then pushed back perpendicular to the aisle. The most efficient systems have platforms that deploy from on top of one another, exposing the next platform as the top one is pushed back. In this case the design of the platform would determine the span that would need to be bridged.

5. Flow Rack
These racks are designed to allow pallets to be loaded in one side of the rack and flow through the rack, usually by gravity, to be removed from the other side. Often designed with 3 sets of rollers perpendicular to the aisle, the roller sets would be on a slight downward angle from entry to exit allowing gravity to move the pallet through the rack. Sometimes there are "brake wheels" installed mid-way on the racks to slow pallets down on their way to the other side. In most cases, there would be a center set of rollers making for a short span. 

6. Cantilever Rack
This rack has uprights parallel to the aisle with support beams cantilevered out from the uprights, perpendicular to the aisle.  These racks are most often used for long items that would not fit into a conventional rack with uprights in the way every 8 feet or so. Pallets used in these racks are almost always custom designed to the specific product they are meant to carry.

7. Supported Rack
​This is usually a beam rack with some kind of support structure that helps with the span from front to back. This could be a series of spanning bars fit perpendicular to the beams front to back, or my personal favorite, the wire deck. In this case a section of heavy gauge wire mesh is placed on the beams, often with extra support members to hold whatever is placed in the rack.

You now know the seven most common types of racks used with rackable pallets. I avoided the panoply of custom solutions, sophisticated AS/RS, stacker-crane systems and the like as each really needs to be evaluated on its own. 

If you still have questions about pallet racks, please feel free to ask them here. Watch for my next post which will go into detail about how pallets interact with racks. Yes, Virginia, thus making them rackable!
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