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The Ultimate Guide To Bespoke & Custom Plastic Pallets

09 Nov 2019

Introduction

Pallets are used widely within any logistics operation, and the advantages of plastic ones are important to consider when deciding what material to use. Even better, custom plastic pallets can help streamline your business activities.

Contents

Chapter One – What is custom plastic pallet?

Chapter Two – Why would a company want to use custom plastic pallets?

Chapter Three – What might influence the type of custom pallet?

Chapter Four – Benefits of custom plastic pallets

Chapter Five – Manufacturing process for custom plastic pallets

Chapter Six – Custom / Bespoke Plastic Pallet FAQs

Chapter Seven – Round Up & Conclusion

Chapter One – What Is A Custom Plastic Pallet?

Pallet requirements can be as diverse as the businesses/ industries that use them. Typically, manufacturers will produce and sell a range of pallets in various sizes. Generally, these pallets are suitable for the vast majority of businesses.

In some instances, however, standard pallets aren’t able to meet certain product and storage needs.

They are built to satisfy the majority of users, which is fine, unless your products are unique or your needs are unique.

This is where custom plastic pallets come in.

When designing and producing a pallet, manufacturers consider a range of factors, such as:

  • How much weight the pallet must be able to hold
  • Its required accessibility and manoeuvrability
  • Product / market standards and legalities

Based on these considerations, custom pallets can be produced to meet specific requirements.

Utilising a range of technologies, traditional plastic pallets can be transformed into a bespoke design of nearly any measurement and material.

Chapter Two – Why Would A Company Want To Use Custom Plastic Pallets?

Whenever manufacturers are selecting or designing a pallet for an application, they consider factors such as how much weight the pallet must be able to hold (load capacity) required accessibility and manoeuvrability (workers must be able to reach and move pallets with their equipment), available warehouse space, market standards and customer budget.

Based on these considerations, manufacturers can create standard or custom plastic pallets that are stackable, rackable, or nestable, made of the right material, and of any dimensions.

Also, manufacturers can design pallets to fit American import standards, as well as international export specifications.

Pallet requirements are as varied as the industries that use them. That’s why, apart from our standard products, we also develop customised designs whose nature, shape, and characteristics are geared precisely to the paths and interfaces in your logistics supply chain – and at no higher cost than necessary.

Typically, manufacturers make and sell standard pallets. However, they can also design custom pallets to fit uncommon storage or shipping needs.

In addition to our many in-stock pallets and containers, we also build custom plastic pallets and custom plastic containers to better fulfill your unique application. Custom plastic pallets can be constructed to meet specific size and weight requirements. Custom pallets are built like a traditional pallet, using either plastic composite lumber or extruded PVC.

Pallet requirements are as varied as the industries that use them. That’s why, apart from our standard products, we also develop customised designs whose nature, shape, and characteristics are geared precisely to the paths and interfaces in your logistics supply chain – and at no higher cost than necessary.

Chapter Three – What Might Influence The Type Of Custom Pallet?

Under the Provision and Use of Work Equipment Regulations 1998, pallets must be suitable for purpose, be maintained and meet requirements when inspected.

Safety is of paramount importance, and the pallets must be stable when stacked, racked or stored.

When pallets are stacked with full loads, the bottom pallet must be able to bear the weight of the entire stack without slipping or fracturing. There may a certain way that the pallets must be stacked for optimum stability, and this should be indicated clearly to avoid errors.

Pallets that are moved by a forklift may need two or four entry points.

When moving stacked pallets, care must be taken and the height of the load should not exceed the pallet’s longest base measurement.

Racking can place pallets under stress, so pallet supports must be adequate.

Custom built plastic pallets can play a vital role in the successful transport, storage and promotion of your goods. However, there are a number of elements that need to be taken into consideration when designing and manufacturing your own pallets, and it is worth taking your time to ensure that all the necessary features are accounted for. They must conform to the appropriate British Standard and be safe to stack and move when fully loaded.

Chapter Four – Benefits Of Custom Plastic Pallets

Fitting:

  • Made exactly to order (sizes and capacity).
  • This type of pallet negates damage caused to the goods as the products are properly fitted.
  • The exact fitting of things is almost seen as unacceptable by the people.
  • The fact that custom pallets are made to your exact requirements and specifications can be extremely helpful in transporting and storing your goods and products.

Additional storage

The most amazing feature that a custom pallet brings is that these pallets are made exactly according to the size you give. The pallets are made exactly in the same manner that you want your goods load fits in perfectly. These pallets negate the damages caused to the goods, as unlike traditional pallets they don’t get damaged in fitting the goods into it. The exact fitting of the pallets also helps in easy packing and storage of the goods.

Better Management of Storage Space

Custom Pallets are made exactly according to client’s requirement thus, it can be properly placed in the warehouse as clients can give the proper measurements of the pallets keeping all the aspects in mind.

Convenience in Inventory Management

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.

This quick count can make inventory management easier and more efficient. This could save your business time which ultimately can save you money.

Chapter 5 – Manufacturing Process For Custom Pallets

There are a number of different manufacturing processes for these pallets.

  1. The high-pressure injection-moulding process starts by melting the plastic material and colourant together in a container. The melt is injected into a mould that is clamped together under pressure.
  2. A low-pressure version of injection moulding is Structural foam moulding. Polyethylene or polypropylene and nitrogen gas are injected into a mould cavity. Heat is applied to activate blowing agents and create foam with a solid skin.
  3. Thermoforming is the most common plastic pallet manufacturing process. Polyethylene pellets are heated to create a nearly liquid plastic sheet. This is pulled into a mould and vacuum-formed.
  4. In the compression-moulding process, a two-piece mould is loaded with plastic using extruders, or even manually. Once filled, a press closes the two moulds. Pressure forces the plastic material into the mould cavities.
  5. Rotational moulding is a process that dates from the 1970s. Powdered plastic is loaded into a mould. This is then heated as it rotates in two planes perpendicular to each other. The rotation ensures distribution and fusion of the plastic.
  6. Profile extruded pallets look like wood pallets and are constructed in a similar way. Plastic is melted, forced through an extruder, then cooled and cut to size. The separate pieces are joined using screws, nails, glue or heat welding.

The type of manufacturing process you may require will differ depending on your budget and pallet specifications. Each option should be looked into to see whether it is the best choice/ most suitable for your needs.

Chapter 6 – Custom/ Bespoke Plastic Pallet FAQs

What Are Custom Plastic Pallets?

Custom or Bespoke plastic pallets are plastic pallets that have been made based on your specific requirements and dimensions. For various reasons you may need a pallet that has specific weight, size or manoeuvrability requirements. Therefore a custom made plastic pallet may be needed.

How Much Does It Cost?

The cost of your custom plastic pallet can vary depending on multiple factors. Such as; manufacturing process, size, load capacity and material. All of these factors can affect the overall cost of your custom pallet.

Why Do I Need A Bespoke Plastic Pallet?

Bespoke Plastic Pallets can be very beneficial. The main benefit is that they can be custom made to suit your requirements in terms of size and dimensions. This can help with the transportation and storage of your products.

What Sizes Can They Come In?

Due to the custom nature of these plastic pallets the sizes can vary depending on your preferences. The plastic pallets can be made to your exact requirements in terms of weight, size and dimensions.

How Much Weight Can Custom Plastic Pallets Support?

The fact that these plastic pallets can be custom made means that the amount of weight these pallets can support is dependent on your requirements. This is one of the major benefits of using Custom made plastic pallets.

What’s The Best Manufacturing Process For My Pallet?

This largely depends again on your specifications and budget. There are lower cost processes and there a higher cost processes. Your requirements can also help you select the most suitable manufacturing process, some are quicker whilst others use less materials.

What Are The Key Things I Need To Consider About My Pallet?

Safety is of paramount importance, and the pallets must be stable when stacked, racked or stored. Another key thing to consider is that when pallets are stacked with full loads, the bottom pallet must be able to bear the weight of the entire stack without slipping or fracturing.

Another consideration is that if pallets are moved by a forklift they may need two or four entry points. Also, when moving stacked pallets, care must be taken and the height of the load should not exceed the pallet’s longest base measurement.

Chapter 7 – Summary And Conclusion

So there we go.

That is our Ultimate Guide to Bespoke and Custom Plastic Pallets. Telling you everything you could possibly want to know about custom plastic pallets and their benefits. From why you might need them, to which manufacturing process is the most suitable for you and everything in between.

Custom built plastic pallets can offer more flexible benefits when they are designed and constructed with certain factors in mind. The Flexible customisation of the plastic pallets to suit you and your business could prove extremely beneficial and improve efficiency.

Make sure you are aware of your pallet requirements and necessary dimensions as this will greatly affect the process and size of your bespoke plastic pallet.

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