Some of the most important aspects of packaging can at times be the most overlooked. It is matter-of-course for much thought and research design to be given to the materials and style selection of product packaging.  An unrecognized but crucial player in the packaging industry however, are the pallets transporting those products.

Pallet design: A tale of two structures

When selecting pallets, it is important to consider the following questions:

  • How much weight will the pallet need to support?
  • How much flex force - or stiffness - can the pallet support? For example, it is important that the pallet not bend, causing the load to shift during transit.
  • How often will the pallet be used?  Is the design for the pallets to be reused or will they be retained for a one-use project?
  • What type of product is being shipped?  Does the product require compliance to specific regulations?

What to consider when considering pallet designs What to consider when considering pallet designs

There are two basic structures used in pallet design.

Stringer Pallets:

  • Built with 2"x 4" wood, plastic or metal "stringers" (long, heavy horizontal timber meant to be used as a support or connector)
  • Designed using runners – components stretching the full length of the pallet - which separate the top and bottom deckboards

Block Pallets:

  • Also built using 2" x 4" wood, plastic or metal "stringers"
  • Designed using blocks or posts that separate the top and bottom deckboards

One last feature to consider when delving into pallet design is process efficiency.  Two-way pallets offer forklift openings on only two ends while four-way pallets offer openings on all four sides to increase accessibility. 

Pallet design and planning for optimal use 

Additional factors for consideration may include:

  • Determine the shipping footprint.   Stringer pallets can be typically found within the US, while the block formation is commonly found in European manufacturing.
  • Determine the daily volume expectation of outgoing shipments.  How many pallets need to be shipped per truck to meet those daily, monthly and annual requirements?
  • How about sustainability? A block pallet, albeit designed using more wood, taller and heavier than the alternative stringer pallet, will lend itself to a long-term investment.  As stated in the beginning, knowing how often the pallets are meant to be used will help to determine exactly which pallet is correct for your application.

There are numerous additional questions that can stand to be answered when selecting a pallet, but taking a few moments to consider each of the facets that go into transporting products will help to deter shipping damages, lost product and material bottom-line spend.