Custom Pallets
When standard sizes do not fit, we design and build custom pallets to your exact specifications. Any size, any material, any requirement.
Describe Your Custom Pallet Needs
Provide your dimensions, load requirements, and any special specifications. We will design a solution and provide a detailed quote.
Built With Reclaimed Lumber When Possible
Even our custom pallets are built with sustainability in mind. Wherever specifications allow, we use reclaimed and recycled lumber from decommissioned pallets. This approach reduces waste, lowers costs, and keeps our environmental footprint as small as possible. When your application requires new lumber, we source from responsible forestry operations.
Custom Pallet Solutions
From simple dimension changes to fully engineered specialty platforms, we handle it all. Here are the most common types of custom pallet projects we take on.
Custom Dimensions
The most common custom request is simply a non-standard size. Maybe your product is 60 inches long and does not fit on a 48-inch pallet. Maybe you need a narrow pallet for tight aisle storage. Whatever your dimensional requirement, we build pallets in any size from small quarter-pallets to massive platforms exceeding 8 feet in any direction.
- Any length, width, and height combination
- Oversized pallets for heavy equipment
- Mini pallets for retail and display
- Odd sizes for unique rack configurations
- Prototype quantities or full production runs
Special Load Requirements
Standard pallets are designed for general-purpose loads, but some cargo demands more. Extremely heavy equipment, concentrated point loads, dynamic loads during transport, or unusual weight distributions all require pallets engineered for the specific application. We design pallets to handle your exact load profile.
- Heavy-duty pallets for equipment over 5,000 lbs
- Reinforced decks for concentrated loads
- Extra stringer or block support
- Anti-slip surfaces for unstable loads
- Engineered using PDS software for optimal design
Branded Pallets
Your pallet can be part of your brand experience. We build pallets with custom stenciling, heat branding, color staining, or printed inserts to display your company logo, handling instructions, or marketing messages. Popular for trade shows, retail displays, and premium product launches.
- Logo stenciling and heat branding
- Custom color staining
- Printed insert panels
- Trade show and display pallets
- Premium unboxing experience pallets
Specialized Designs
Some cargo requires truly unique pallet designs. We have built pallets with integrated cradles for cylindrical objects, pallets with raised edges to contain liquids, pallets with cutouts for forklift clearance, and pallets designed to interlock with specific equipment. If you can describe it, we can build it.
- Cradle pallets for drums and cylinders
- Spill-containment pallets with raised edges
- Cutout pallets for forklift clearance
- Interlocking pallets for modular systems
- Skids, crates, and hybrid designs
Custom Pallet Design Process
From initial conversation to final delivery, our custom pallet process is designed to be straightforward and efficient. Most custom orders are completed within 5-10 business days.
Consultation
We start with a detailed conversation about your needs. What are you shipping? How heavy is it? What are the dimensions? Do you need racking compatibility? Heat treatment? We ask the right questions to understand your requirements fully.
Design & Engineering
Our team designs your custom pallet using industry-standard Pallet Design System (PDS) software when needed. We optimize for strength, weight, cost, and material availability. You receive a detailed specification sheet for approval before we build.
Prototype & Approval
For new designs, we build a prototype for your inspection and testing. This ensures the pallet meets your requirements before we commit to a full production run. Adjustments are made at this stage at no additional cost.
Production & Delivery
Once approved, we move to full production. Custom pallets are built in our facility using your specified materials and construction methods. We handle delivery directly to your location on your schedule.
Material Options for Custom Pallets
Reclaimed Wood
Our preferred material for custom pallets. Reclaimed lumber from decommissioned pallets is sorted, inspected, and reused in new constructions. This is the most sustainable option and often the most affordable. Ideal for general-purpose custom pallets where pristine appearance is not required.
New Hardwood
Oak and other hardwoods provide the highest strength and durability for custom pallets. Ideal for heavy-duty applications, export pallets, and any situation that demands maximum load capacity and resistance to damage. Hardwood pallets are heavier but significantly stronger than softwood alternatives.
New Softwood
Southern yellow pine and other softwoods are the most common materials for new pallet construction. They offer a good balance of strength, weight, and cost. Softwood pallets are lighter than hardwood, making them more cost-effective for shipping applications where weight matters.
Treatment & Finishing Options
Custom pallets can be treated and finished to meet specific requirements. From ISPM-15 heat treatment for international shipping to custom staining for branded displays, we offer a full range of treatment options.
Heat Treatment (ISPM-15)
Required for international shipping. The pallet core temperature is raised to 56 degrees Celsius for at least 30 minutes, eliminating pests. Each treated pallet receives the official ISPM-15 stamp.
Kiln Drying
Reduces moisture content to below 19%, preventing mold growth, reducing weight, and improving dimensional stability. Essential for sensitive products and indoor applications.
Custom Staining
Apply custom colors to match your brand identity. Available in a wide range of wood stain colors. Popular for trade show displays, retail environments, and branded shipping.
Sanding & Finishing
Smooth sanded surfaces for applications where splinter-free handling is important. Available in various grit levels from rough sanding to furniture-grade smoothness.
Anti-Slip Coating
Non-slip coatings applied to deck boards prevent products from shifting during transport. Especially important for smooth-bottomed containers and shrink-wrapped loads.
Fire Retardant Treatment
Chemical treatment that reduces flammability. Required or recommended for pallets used in certain storage environments, data centers, and facilities with strict fire codes.
Custom Pallets for Every Industry
We have built custom pallets for businesses across dozens of industries. Here are some of the most common industries that need non-standard pallet solutions.
Aerospace & Defense
Precision pallets for aircraft components, military equipment, and sensitive instruments. Often require custom cradles, tie-down points, and shock-absorbing features.
Automotive Manufacturing
Custom pallets for engine blocks, transmissions, body panels, and assembly line components. Designed for specific part profiles and automated handling systems.
Heavy Equipment
Oversized, heavy-duty pallets and skids for industrial machinery, generators, transformers, and construction equipment. Engineered for extreme loads.
Art & Antiques
Padded, cushioned custom pallets for fine art, antiques, and museum pieces. Built to minimize vibration and impact during transport of irreplaceable items.
Medical Devices
Custom pallets meeting FDA and cleanroom requirements for medical device manufacturing and distribution. Designed for ESD-sensitive and sterile environments.
Agriculture
Custom pallets for produce bins, livestock feed, equipment parts, and bulk agricultural products. Built to handle outdoor conditions and rough handling.
Frequently Requested Custom Dimensions
While we build pallets in any size, these are the custom dimensions we produce most frequently. If your size is listed here, we may have templates ready for faster production.
| Size | Common Industry | Typical Load | Lead Time |
|---|---|---|---|
| 60" x 48" | Heavy Equipment | Up to 4,000 lbs | 5-7 days |
| 72" x 48" | Machinery / Aerospace | Up to 5,000 lbs | 5-7 days |
| 36" x 36" | Retail / Quarter Pallet | Up to 1,500 lbs | 3-5 days |
| 48" x 24" | Beverage / Half Pallet | Up to 1,800 lbs | 3-5 days |
| 96" x 48" | Industrial / Oversized | Up to 6,000 lbs | 7-10 days |
| 44" x 44" | Drum / Barrel Shipping | Up to 2,500 lbs | 3-5 days |
| 60" x 40" | Automotive Parts | Up to 3,500 lbs | 5-7 days |
| Any Custom | Your Specification | Engineered | 5-10 days |
Advanced Custom Pallet Features
Beyond standard dimensions and materials, we offer a range of specialized features for demanding applications.
Notched Stringers
Custom notch patterns for specific forklift types. Standard, shallow, or deep notches cut to your equipment specifications for optimal fork entry.
Wing Pallets
Extended deck boards that overhang the stringers, creating extra surface area for loads wider than the pallet base. Common in paper, textile, and mattress industries.
Heat Treated (ISPM-15)
Full heat treatment to international phytosanitary standards. Required for all wood pallets used in international export shipping.
Fumigated (MB)
Methyl bromide fumigation for destinations that require it. Note: MB treatment is being phased out globally in favor of heat treatment.
Anti-Slip Surfaces
Textured or coated deck surfaces that grip smooth-bottomed loads. Essential for shrink-wrapped products, glass containers, and polished surfaces.
Reinforced Decks
Extra thick deck boards or additional support for concentrated point loads. Engineered for specific load profiles using PDS software.
Lead Times & Minimum Orders
Custom pallet production timelines depend on design complexity, material availability, and order volume. Here is what to expect so you can plan accordingly.
Minimum Order Quantities
For standard custom sizes, our minimum order is 25 pallets. For fully engineered designs requiring new templates or prototypes, minimums may start at 50 units. We can produce single prototypes for testing before committing to a full production run.
Standard custom min
Prototype available
Engineering Consultation
Not sure what design you need? Our engineering team provides free consultations for custom pallet projects. We use Pallet Design System (PDS) software to optimize your pallet for strength, weight, material cost, and production efficiency. This ensures you get the best possible design for your specific load requirements.
Schedule ConsultationCustom Pallet Case Studies
Aerospace Component Manufacturer
Needed custom 72x60 pallets with integrated cradles to secure cylindrical engine housings during ground transport. Standard pallets caused shifting and potential damage to machined surfaces.
Designed and built hardwood pallets with routed cradle channels, anti-slip coating, and foam-lined contact points. Each pallet was heat-treated for potential international transport.
Zero transit damage in over 200 shipments. Client estimated $45,000 in avoided damage claims in the first year. Design became the standard for all engine housing shipments.
Regional Brewery Distribution
Brewery needed half-pallets (48x24) for retail displays that could hold keg weight but look attractive on the store floor. Standard commercial pallets were too large and visually unappealing.
Built sanded, stained half-pallets with the brewery logo heat-branded into the deck. Used reclaimed oak for character and durability. Designed for forklift and hand-truck access.
Deployed in 35 retail locations. The branded pallets became part of the brewery marketing strategy. Reorder of 500 additional units within 6 months.
Medical Device Clean Room
Medical device manufacturer needed pallets for a Class 100,000 cleanroom that met FDA requirements, produced no particulates, and could be fully sanitized between uses.
Recommended hygienic plastic pallets rather than custom wood. Sourced closed-deck, smooth-surface HDPE pallets in white with RFID tracking tags molded in. Each pallet was documented with a certificate of compliance.
Passed all FDA audit inspections. RFID integration enabled automated inventory tracking. Client reduced cleanroom contamination events by 60%.
Custom Pallet FAQs
Custom pallet pricing depends on dimensions, materials, complexity, and volume. Simple dimension changes (different size but standard construction) typically cost 10 to 30 percent more than standard pallets. Fully engineered specialty designs with custom features can cost 50 to 100 percent more. However, the right custom pallet often saves money overall by reducing product damage, improving handling efficiency, and eliminating the need for additional packaging.
Yes. We strongly recommend prototyping for new custom designs. We will build one or a small batch of prototypes for you to test with your actual products and in your actual handling environment. Prototype costs are credited toward your production order. This approach eliminates the risk of committing to a large order that does not meet your expectations.
Whenever specifications allow, we use reclaimed and recycled lumber from decommissioned pallets. This reduces cost, minimizes waste, and lowers environmental impact. When your application requires new lumber — for strength, appearance, or regulatory reasons — we source from responsible forestry operations. We will always discuss material options and their trade-offs during the design phase.
That is what our engineering consultation is for. Tell us what you are shipping (dimensions, weight, shape, fragility), how it will be handled (forklift, pallet jack, crane), where it is going (domestic, export), and any special requirements. Our team will design the optimal pallet using PDS software and present you with options at different price and performance levels.
Yes. If you have an existing custom pallet design that you want us to replicate, simply provide a sample pallet or detailed drawings and we will match it. We can also improve on existing designs if you have identified issues with the current version. Many clients come to us after their previous supplier could not maintain quality or meet delivery schedules.
Check Our Used Inventory First
Before ordering custom pallets, it is worth checking whether we already have what you need in our used pallet inventory. We stock a wide variety of sizes beyond the standard GMA 48x40, and you might find your "custom" size is actually a common size in a different industry. Used pallets in your size would save you money and reduce your environmental impact compared to building new custom pallets.