Standard pallet sizes work for the vast majority of applications. But when your product has unusual dimensions, extreme weight, or special handling requirements, a custom pallet isn't a luxury — it's a necessity.
Common scenarios that call for custom pallets include: oversized industrial equipment that won't fit on standard pallets, delicate instruments that need integrated cushioning or restraints, extremely heavy loads that exceed standard capacity ratings, and products with unusual shapes that require custom deck configurations.
The custom pallet design process starts with understanding your product. We need to know the exact dimensions, weight, center of gravity, fragility, and any environmental sensitivities (moisture, temperature, static). We also need to understand how the pallet will be handled — forklifted, craned, hand-carried?
Our engineering team uses the NWPCA's Pallet Design System (PDS) to model the structural performance of custom designs. This allows us to optimize material usage while ensuring the pallet meets or exceeds your load requirements. Over-engineering wastes material; under-engineering risks failure.
Material selection is a key decision. Hardwood (oak, maple) for heavy loads. Softwood (pine, spruce) for lighter loads and cost savings. Plywood for smooth deck surfaces. Composite materials for chemical resistance. Metal reinforcements for extreme loads. Or combinations of all of the above.
We build custom pallets using recycled materials whenever possible. Reclaimed hardwood from dismantled pallets often provides excellent material for custom applications at lower cost and environmental impact than new lumber.
Turnaround time for custom pallets is typically 5-10 business days for standard orders, with rush options available. We produce prototypes for approval before full production runs, ensuring the design meets your needs before we build in volume.