Packaging Corner: Looking at the 1% of pallets

When you think pallets, you probably think wood and maybe plastic. That’s to be expected with approximately 92% of the billions of pallets worldwide constructed of wood, while plastic comprises around 5%.

“Metal, paper and presswood pallets are estimated to be roughly 1% each of the market,” says Ralph Rupert, manager of unit load technology at Millwood. “That truly makes them alternative materials when it comes to unit load handling.”

Each material’s specific properties make them ideal for very niche applications, he continues: “Economically, a traditional wood pallet tends to make the most financial sense for the majority of load handling needs. But when load bearing capacity, functionality and application economics align just so, an alternative pallet material can be the right choice.”

Because of their rigidity, durability and flame resistant properties, pallets made of aluminum or steel are ideal for the heaviest, most dense loads including hot castings and other manufacturing applications. They also tend to be one of the most expensive pallet types and rarely leave the facility in which they are used.

Paper-based pallets come in a range of formats, including formed corrugated blocks, glued and laminated stringers, honeycomb structures and spiral round tubes. “They hold up to 1,000 pounds and are ideal in situations where total load weight is a critical, such as air freight,” Rupert explains. “Or, they’re good for a rigid product that needs to be kept off the floor and handled with fork tines, such as a stack of interior doors.”

Presswood pallets, which are formed from wood chips and resin at high temperatures and pressure, offer the primary advantage of nestability, Rupert continues.

“A standard trailer can only hold about 550 traditional wood pallets, whereas twice as many presswood pallets can fit. That makes them ideal in a closed-loop system in terms of cost per return trip,” Rupert says. “And, at a price point roughly a third less costly than nestable plastic pallets, they’re often a more economical choice.”