Pallet Size Guide

Consider custom sizing when your product dimensions do not align well with any standard pallet size, when you have overhang exceeding 1 inch on any side, when your product weight exceeds the capacity of standard grades, when your racking system has non-standard beam spacing, or when your shipping container requires specific pallet dimensions for optimal space utilization. Custom pallets often cost more per unit but can save money overall by reducing product damage, improving load stability, and maximizing space utilization.

Start by measuring your product (including packaging) at its widest points. Add 0.5 to 1 inch of clearance on each side for safe handling. Consider how products will be arranged on the pallet (single layer, double-stacked, nested). Account for stretch wrap or banding that adds to the footprint. Then measure your racking or storage space to ensure the pallet fits. Finally, check your truck or container interior dimensions to confirm that the custom size allows efficient loading without wasted space.

Custom pallet lead times are typically 5 to 10 business days from order confirmation, depending on the complexity of the design and the quantity ordered. Minimum orders for custom sizes start at 50 units for simple dimension changes and 100 units for complex designs requiring non-standard construction. We provide detailed specifications and a per-unit quote before manufacturing begins. For recurring custom orders, we can maintain safety stock at our facility for faster turnaround.

Yes. Custom pallets can be heat-treated to ISPM-15 standards just like standard sizes. The heat treatment process is independent of pallet dimensions, though very large or thick pallets may require slightly longer treatment times to ensure the core temperature requirement is met throughout the wood. All custom heat-treated pallets receive the official IPPC stamp and full documentation for customs compliance.

The flat surface of a pallet, consisting of multiple boards laid side by side. The top deck supports the load directly. The bottom deck provides a base surface for racking or floor contact. Deck board width, thickness, and spacing affect load distribution and the types of products the pallet can safely carry.

A continuous, structural beam (typically 2x4 or 3x4 lumber) running the full length of a stringer pallet. Stringers are the primary load-bearing elements that connect the top and bottom decks. Most standard pallets use three stringers: two on the outside edges and one in the center.

A solid block of wood (typically 4 to 6 inches square) used in block pallet construction. Blocks are placed at the corners, center edges, and center of the pallet instead of full-length stringers. Block construction allows four-way forklift entry from all sides. The Euro pallet (EUR 1) is the most common block pallet design.

A rectangular cutout in the bottom of a stringer that allows forklift tines to enter from the side. Notches typically measure about 1.5 inches deep by 9 inches wide. Notched stringers convert a two-way entry pallet into a partial four-way entry pallet, enabling pallet jack access from all four sides while maintaining stringer strength.

A beveled (angled) cut on the leading edge of the bottom deck boards. The chamfer creates a ramp that allows forklift tines and pallet jack forks to slide under the pallet more easily, reducing snag points and speeding up material handling. Chamfers are typically cut at a 45-degree angle and are 0.75 to 1 inch deep.

The outermost top deck board on each side of the pallet. Lead boards take the most abuse during handling and are the first boards that forklift tines contact when approaching from the deck side. On quality pallets, lead boards are typically wider and thicker than interior boards for added durability.

The gap between individual deck boards on the top or bottom surface. Spacing affects how evenly the load is distributed and what types of products can be placed on the pallet. Tighter spacing provides better support for small or flexible items. Wider spacing reduces material cost and pallet weight but may require slip sheets for small products.

The distance that a product extends beyond the edge of the pallet deck. Overhang creates stability risks during transport and stacking, increases the chance of product damage, and can cause problems with automated handling equipment. Industry best practice is to keep overhang under 1 inch on any side.

A pallet where the deck boards are cut exactly even with the outer edges of the stringers or blocks. Flush pallets have clean, uniform edges and fit precisely into standard racking without any overhang of the pallet structure itself. Most GMA pallets and automated warehouse pallets use flush design.

A pallet where the top or bottom deck boards extend beyond the edge of the stringers or blocks. Wings make it easier to pass slings under the pallet for crane lifting. Wing pallets are common in lumber, steel, and heavy manufacturing where crane handling is standard.

The opening in a pallet through which forklift tines or pallet jack forks are inserted for lifting. Two-way entry allows access from two opposite sides only. Four-way entry allows access from all four sides. Partial four-way entry (via notched stringers) allows full fork entry from two sides and pallet jack entry from the other two.

Another term for the bottom structural members of a pallet, particularly when they are continuous boards rather than individual blocks. Runners are the components that contact the floor or racking surface. In stringer pallets, the bottom boards that run perpendicular to the stringers serve as runners.