Built to Specification

CUSTOM PALLETS

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Engineered for Your Needs

When standard pallets won't cut it, we design and build custom solutions engineered for your specific load requirements, dimensions, and handling equipment. From prototype to production runs of 10,000+ units, we deliver precision-built pallets that solve your unique material handling challenges.

Our in-house engineering team works directly with your operations staff to design pallets that maximize efficiency, reduce damage, and integrate seamlessly with your existing warehouse systems.

Custom pallet manufacturing

Custom Capabilities

Non-Standard Dimensions

Any length, width, or height. We've built pallets from 24x24" to 96x120" and everything in between. Odd shapes and sizes our specialty.

Heavy-Duty Construction

Engineered for loads up to 10,000 lbs. Reinforced stringers, doubled deck boards, and hardwood construction for extreme applications.

Specialty Materials

Plastic, metal, or wood construction. Food-grade materials, cleanroom-compatible designs, or corrosion-resistant options available.

Custom Features

Built-in handles, forklift pockets, stacking notches, RFID tags, company branding, or special coatings per your requirements.

Prototyping

Single prototype units available. Test your design in real conditions before committing to production quantities.

Volume Production

Consistent quality across runs of 1,000 to 100,000 units. We maintain tooling and specifications for repeat orders.

Custom pallet design process

Design Process

1

Requirements Analysis

We document your product dimensions, weight, handling methods, storage systems, and shipping requirements. Site visits available for complex applications.

2

Engineering Design

CAD drawings and load calculations provided. We analyze stress points, optimize material usage, and ensure design meets all relevant safety standards.

3

Prototype Build

First unit built for your approval. Test with your actual products and handling equipment. Design revisions included at no extra charge.

4

Production Setup

Manufacturing templates created, jigs built, and quality control standards established. First production run closely monitored.

5

Delivery & Support

Scheduled delivery per your timeline. We maintain design files and tooling for quick reorders. Modifications and refinements supported long-term.

Custom pallet applications

Industries We've Served

Aerospace

Precision pallets for aircraft components, cleanroom-compatible construction

Automotive

Heavy-duty pallets for engine blocks, transmissions, and body panels

Food Processing

USDA-compliant plastic pallets, easy-clean surfaces, bacteria-resistant materials

Pharmaceuticals

GMP-compliant designs, batch tracking, contamination-free materials

Glass & Ceramics

Padded surfaces, custom dividers, shock-absorbing features

Electronics

ESD-safe materials, conductive options, precise spacing for delicate components

Custom pallet solutions

Why Choose Custom?

Optimize Space

Pallets sized to maximize truck loading, warehouse racking, and product fit reduce wasted space. Customers report 15-30% space savings with optimized pallet dimensions.

Reduce Damage

Purpose-built support structures protect fragile products. Custom features like edge protection and shock absorption cut product damage claims significantly.

Improve Handling

Designed for your specific forklifts, pallet jacks, and automated systems. Reduce handling time and improve worker safety with ergonomic features.

Long-Term Value

Higher initial cost offset by years of reliable service. Custom pallets often outlast standard pallets by 3-5 years when engineered for specific applications.

Pricing & Lead Times

Prototype (1-5 units)
Includes engineering & design
5-7 days
$150-500/unit
Small Run (10-100 units)
Testing & validation quantities
2-3 weeks
$50-200/unit
Medium Run (100-1,000 units)
Initial production deployment
3-5 weeks
$30-100/unit
Volume (1,000+ units)
Full production quantities
6-10 weeks
$25-75/unit

Frequently Asked Questions

What information do you need to design a custom pallet?

Share load weight, product dimensions, stacking requirements, handling method (forklift or pallet jack), and destination so we can design the right deck and stringer layout.

Do you provide drawings or load calculations?

Yes. We can provide shop drawings and recommend lumber specs and fasteners to meet your load rating and handling needs.

Can custom pallets be heat-treated for export?

Absolutely. We heat-treat and stamp custom builds to ISPM 15 standards with documentation for international shipments.

What sizes can you manufacture?

We build any footprint or height, including oversized, narrow aisle, and specialty formats that standard pallets cannot accommodate.

What are typical lead times for custom builds?

Most custom orders ship in 3–7 business days depending on complexity and volume. We confirm timelines in the quote.

Can you add custom blocking, notching, or stenciling?

Yes. We offer chamfering, notched stringers, wing pallets, stencil logos, corner boards, and banding solutions on request.

Is there a minimum order for custom pallets?

Small runs are possible, but pricing improves with volume. We will price prototypes and then scale production as needed.

Do you work with hardwood and softwood options?

We source both hardwood and softwood and will recommend the best choice for strength, weight, and budget.

Can you rush a custom order?

When lumber and production slots are available, we can prioritize rush builds. Tell us your deadline and we will confirm feasibility.

Do you test prototypes?

For critical loads, we can build and test prototypes before full production so you can validate fit, handling, and durability.