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Pallet types

Plastic pallet: types, load ratings and how to specify one

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In short

A plastic pallet is a molded HDPE or polypropylene pallet, usually chosen from a catalog rather than designed, because new injection molds only pay off at very high volumes. Plastic pallets carry three ratings (static, dynamic and racking), weigh roughly 14 to 70 lb in the 48 x 40 class and are exempt from ISPM 15.

On this page
  1. What is a plastic pallet?
  2. How plastic pallets are made
  3. Styles
  4. How plastic pallet load ratings work
  5. When to use a plastic pallet
  6. When a wood pallet is the better choice
  7. Plastic vs wood pallets
  8. How to specify a plastic pallet

What is a plastic pallet?

Plastic pallets are made from resin, mostly high-density polyethylene (HDPE) or polypropylene (PP), by molding or by assembling extruded plastic boards. They are sold as catalog models from makers such as ORBIS, Buckhorn, CABKA, Craemer and Rehrig, and rented in the iGPS pool.

palletdesign.ai does not design plastic pallets. It designs wood stringer, block and skid pallets. This page explains plastic pallets so you can compare them with a wood design and specify them to a supplier.

How plastic pallets are made

Process Character Custom realistic?
Injection molded Tight dimensions, most rackable and nestable catalog pallets No: one processor puts custom molds at orders over 50,000 units
Structural foam Rigid, heavy-duty, rackable Rarely: a new tool is still a large investment
Thermoformed (single or twin sheet) Light to heavy duty; twin sheet can hold steel inside Yes at medium volume
Rotomolded Hollow, thick-walled, very durable Yes at low volume, but slow cycles
Compression molded Tolerates recycled resin; export pallets Catalog
Extruded profile (plastic lumber) Built like a wood pallet from plastic boards Yes: no tooling, small minimums

Styles

  • Nestable: legs or feet (typically 9) nest into the pallet below. Cheapest and lightest, not rackable.
  • Stackable: runner or perimeter base for floor stacking; may not be rackable.
  • Rackable: continuous runners or a perimeter or cruciform base, often steel-reinforced.
  • Hygienic: closed top and bottom, washable, for food and pharma.
  • Export: thin-wall or compression-molded, often recycled resin.

How plastic pallet load ratings work

Plastic pallets are sold with three numbers:

Rating Support Example (Buckhorn PU48400633, manufacturer's figures)
Static Flat floor, bottom of a stack 30,000 lb
Dynamic On forks, pallet jack or conveyor 5,000 lb
Racking Spanning rack beams, nothing underneath 2,800 lb (edge racking)

These are not comparable across vendors unless you know the test standard, the rack direction and span, the load distribution, temperature and load duration. Plastic ratings are governed by stiffness and creep, not breaking strength; see creep and ISO 8611.

When to use a plastic pallet

  • Closed loops with many trips, where durability outweighs price.
  • Food, pharma and washdown areas that need hygienic, cleanable pallets.
  • Export where ISPM 15 must be avoided entirely.
  • Automated systems that benefit from consistent dimensions.

When a wood pallet is the better choice

  • One-way shipments: indicative new plastic prices run about $40 to $200 against roughly $10 to $25 for a new GMA wood pallet, per vendor guides.
  • Non-standard sizes at normal volumes, where a new mold is uneconomic.
  • Fire-sensitive storage: unlisted plastic pallets can raise the commodity class for sprinkler design; plastic pallets listed to UL 2335 or FM 4996 are treated as wood.

Plastic vs wood pallets

Plastic Wood
Weight, 48 x 40 class About 14 to 70 lb About 30 to 70 lb
Custom geometry Options only for molded pallets Fully custom
Rackable Rackable models only Designed in
ISPM 15 Exempt Treatment and mark required
Indicative new price $40 to $200 $10 to $25 (GMA)

How to specify a plastic pallet

Describe the requirement and let suppliers propose models: footprint and maximum height; style (nestable, stackable, rackable, hygienic); open or closed deck; base (feet, runners, perimeter, cruciform); 2-way or 4-way; resin (HDPE, PP, virgin or recycled); reinforcement; fire rating; food-contact letter of compliance; temperature range; color, branding and RFID; and the load requirement: weight, distribution, floor stacking, forklift or conveyor, and rack direction and beam span. Ask each supplier to state the standard behind its ratings. A reference model "or equal" helps.

For a wood alternative, start with a 48 x 40 block pallet, which gives four-way handling like most plastic designs.

Questions

Are plastic pallets stronger than wood?
It depends on the rating. Plastic pallets often have very high static ratings but lower racking ratings because plastic creeps under sustained load. Compare static, dynamic and rack figures for the same support condition.
Do plastic pallets need ISPM 15?
No. Plastic pallets are exempt from ISPM 15.
Can I get a custom-size plastic pallet?
Rarely in injection-molded plastic, because a new mold needs very high volume. Thermoformed, rotomolded and extruded-profile pallets can be made to custom sizes at lower volumes.
Does palletdesign.ai design plastic pallets?
No. It designs wood stringer, block and skid pallets, which you can use as a comparison or alternative.

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