Complete Pallet Guide

Introduction to Pallets

Pallets are the backbone of modern logistics and warehousing. This comprehensive guide will help you understand pallet types, grades, uses, and how to choose the right pallet for your needs.

Pallet Types

Stringer Pallets

Stringer pallets use boards called stringers to support the top deck. They typically offer 2-way entry (forklift can enter from two sides). This is the most common and economical pallet design.

Block Pallets

Block pallets use blocks (typically nine) instead of stringers for support. This design allows 4-way entry, meaning forklifts and pallet jacks can enter from all four sides. Block pallets are generally stronger but more expensive.

Standard Sizes

• 48x40 inches: The GMA standard, most common in North America
• 42x42 inches: Common in telecommunications and paint industries
• 48x48 inches: Often used for drums and large containers
• 40x48 inches: Similar to GMA but with dimensions reversed
• Custom sizes: Available for special applications

Understanding Pallet Grades

Grade A (Premium)

• New or like-new condition
• No visible damage or repairs
• Clean appearance
• Best for export, display, or high-value goods
• Most expensive option
• Longest lifespan

Grade B (Standard)

• Used but structurally sound
• May have minor repairs
• Some cosmetic wear acceptable
• Best for general warehouse use
• Best value for most applications
• 30-50% less expensive than Grade A

Grade C (Economy)

• Heavy wear but functional
• May have multiple repairs
• Suitable for light loads
• Best for one-time use or DIY projects
• Lowest cost option
• Limited remaining lifespan

Choosing the Right Pallet

Consider Your Application

Export/International Shipping:

• Choose Grade A pallets
• Ensure ISPM 15 heat treatment compliance
• Consider whether you need the pallets returned

Domestic Shipping:

• Grade B typically sufficient
• Consider pallet return/exchange programs
• Match pallet to product value and handling requirements

Storage Only:

• Grade B or C acceptable depending on load
• Consider static load vs. dynamic load requirements
• Inspect rack systems for compatibility

Load Considerations

Weight: Standard pallets handle 2,500-4,000 lbs, but verify for your specific load.

Distribution: Evenly distributed loads are safest. Concentrated loads may require reinforced pallets.

Height: Stacking height affects pallet requirements. Taller stacks need stronger pallets.

Handling Equipment

• Forklift: Can handle 2-way or 4-way entry pallets
• Pallet Jack: Requires proper entry notches
• Automated Systems: May require specific dimensions and quality standards

Pallet Maintenance

Inspection Guidelines

Regular inspection prevents accidents and extends pallet life. Check for:

• Broken or missing boards
• Protruding nails or fasteners
• Cracks in structural components
• Signs of rot or pest damage
• Excessive wear on load-bearing surfaces

When to Repair vs. Replace

Repair if:

• Structural components are intact
• Only a few boards need replacement
• Repair cost is less than 50% of replacement cost

Replace if:

• Major structural damage
• Rot or pest damage
• Multiple components broken
• Safety concerns

Environmental Considerations

Sustainability Benefits

• Reusable for many years
• Repairable to extend lifespan
• Recyclable at end of life
• Made from renewable resource (wood)
• Lower carbon footprint than single-use packaging

Recycling Options

• Repair and reuse
• Dismantle for parts
• Grind for mulch
• Convert to biomass fuel
• Recycle metal components separately

Cost Optimization Strategies

Reduce Pallet Costs

• Choose the appropriate grade - don't over-spec
• Implement a repair program
• Buy in volume for discounts
• Establish pallet return/exchange systems
• Track pallet inventory to prevent loss
• Consider pallet pooling programs

Maximize Pallet Life

• Train staff on proper handling
• Implement regular inspection programs
• Repair minor damage promptly
• Store pallets properly when not in use
• Match pallet grade to application

Safety Guidelines

Safe Handling Practices

• Always inspect pallets before use
• Don't exceed weight ratings
• Ensure loads are properly secured and balanced
• Use appropriate equipment for pallet size and weight
• Train employees on pallet safety
• Remove damaged pallets from service immediately

Storage Safety

• Stack pallets no more than 6 feet high when empty
• Store on level ground
• Keep fire lanes clear
• Avoid moisture exposure
• Maintain adequate clearances

Industry-Specific Considerations

Food & Beverage

• May require Grade A pallets for cleanliness
• Consider food-safe treatments
• Regular cleaning may be necessary
• Check for pest damage frequently

Pharmaceuticals

• Often requires Grade A or specialized pallets
• May need specific certifications
• Cleanliness is critical
• Traceability may be required

Manufacturing

• Grade B typically appropriate
• Consider internal pallet pools
• Match pallet to automation requirements
• Implement repair programs

Retail

• Display pallets should be Grade A
• Backroom storage can use Grade B
• Consider appearance for customer-facing areas
• Implement return programs with suppliers

Regulatory Compliance

ISPM 15 (International Standard)

Required for international shipping to prevent pest transfer. Pallets must be:

• Heat treated to 56°C for 30 minutes
• Marked with official ISPM 15 stamp
• Properly documented

Local Regulations

Some jurisdictions have specific requirements for pallet storage, disposal, or treatment. Check local regulations or ask us about compliance in your area.

Working with Norfolk Pallets

Our team can help you select the right pallets for your application, establish cost-effective pallet programs, and provide ongoing support. We offer:

• Expert consultation on pallet selection
• Custom pallet programs for your business
• Repair and recycling services
• Regular delivery schedules
• Quality assurance on all pallets
• Competitive pricing and volume discounts

Need More Information?

This guide covers the basics, but every business has unique needs. Contact Norfolk Pallets today to discuss your specific requirements. Fill out the form above or email [email protected] to speak with our pallet experts.