How to Extend Pallet Lifecycle with Proper Handling and Storage

Wood vs. Plastic Pallets: Key Differences

• Material Properties: Wood pallets are heavier and made of boards nailed or screwed together. They can be repaired easily by replacing broken boards or nails. However, wood is porous: it absorbs moisture and can rot or warp when wet. Plastic pallets are made of molded polyethylene or polypropylene. They resist water, mold, and insects, and are lighter in weight. Plastic does not corrode or rust, but it can become brittle in extreme cold or deform under very high heat.
• Durability: Generally, high-quality plastic pallets last many more load cycles than wooden ones. Wood will crack and splinter over repeated heavy use, while plastic tends to bend or craze (micro-crack) before breaking. That said, wood is often cheaper and easier to repair on-site. Choosing the right type depends on the environment: for example, food and chemical industries often prefer plastic for its hygiene and chemical resistance, while general distribution may use treated wood.
• Hygiene and Maintenance: Plastic pallets clean easily with water and mild detergent; they do not harbor mold as wood can. Wooden pallets require more careful maintenance to prevent infestations (e.g. termites, beetles) and mold. Many wooden pallets for export are heat-treated or fumigated to meet regulations (ISPM-15 standard).

Understanding these differences helps tailor handling and storage strategies. In practice, many facilities use both types and should handle each according to its strengths and weaknesses.

Best Practices for Pallet Handling

Proper handling is critical to avoid mechanical damage. Train all material handlers and forklift operators in these techniques:

• Inspect Before Use: Visually check every pallet for cracks, loose boards, missing deck boards, or exposed nails. Do not use damaged pallets for heavy loads. Cracks or splinters are fatigue signs in wood; brittleness or deformation in plastic signals the pallet should be retired or repaired.
• Forklift Use: When lifting a pallet with a forklift:
• • Level forks: Keep the forks flat and enter the pallet squarely. Skewed forks or a tilted mast can pry off the front or rear deck board.
  • Full fork entry: Push the forks well under the pallet’s deck. At least 2/3 of fork length should go through for stability. Uneven entry (one fork shorter) can break boards or twist the pallet.
  • Center the load: Place the forks so the pallet load’s center of gravity is balanced. Centering heavy items prevents tipping and reduces stress on pallet corners.
  • Lower gently: Avoid dropping the pallet abruptly onto racking or the floor. A controlled descent prevents jolts that can crack boards or loosen fasteners.
  • Keep load low: Transport loads as low to the ground as safely possible to improve stability and visibility.
  • Avoid skidding or pushing: Never use the forklift to slide pallets across the floor or ram them into racks. Dragging can shear off boards or axles, and can damage flooring.
  • Hand and Jack Use: For smaller moves, use pallet jacks or manual stackers carefully:
  • • Ensure the jack forks fit into the pallet’s notches fully before lifting.
    • Pump the jack smoothly; avoid sudden lifts that could unseat a weak deck ​board.
    • Do not twist or cant the pallet on the jack, as this creates uneven stress.
• Gentle Handling: Never drop empty or loaded pallets from vehicles or high platforms. Set them down gently after unloading. Avoid climbing on pallets or allowing people to stand on pallet stacks (unsafe and can damage the pallet).
• Load Securing: Use straps, stretch wrap, or bands to secure odd-shaped or tall loads. Unstable loads can shift and exert uneven forces on the pallet, causing breakage.
• Protect Edges: Be cautious of forklift collisions with pallet corners and stringers (the side supports on wood pallets). Even a light sideswipe can chip off a corner or deform a plastic runner.

In summary, correct handling means controlled, precise movements. Encourage a culture of careful material handling. Regular safety briefings or visual guides (e.g. posters of forklift dos and don’ts) can reinforce these practices.

Best Practices for Pallet Storage

Proper storage minimizes environmental and static load stress:

• Clean, Dry Environment: Store pallets in a well-ventilated warehouse if possible. Wooden pallets must be kept dry – moisture causes swelling, warping, mold, and rot. Stack wood pallets on racks, shelves, or wooden dunnage to raise them off damp floors. Plastic pallets resist water but should still be kept relatively dry to prevent dirt accumulation and allow easy inspection.
• Indoor vs. Outdoor: Whenever possible, store pallets indoors. If outdoor storage is unavoidable:
• • Wood: Cover stacks with waterproof tarps or place under a canopy. Do not lean pallets against walls where rain can pool. Ensure pallets remain a few inches off the ground (place on blocks) to avoid ground moisture.
  • Plastic: Although water won’t damage plastic material, prolonged UV exposure will cause some plastics to become brittle or fade. Use UV-resistant plastic pallets or cover them if stored in direct sunlight. Extreme heat from sun can also soften plastic slightly; keep them shaded or under roof.
• Stacking Practices:
• • Uniform Stacks: Only stack pallets of the same size and type together. Mixing sizes can cause misalignment and leaning.
  • Flat and Even: Lay each pallet flat; do not tilt or lean on edge. Align stringers or runners so the stack is flush. For wood pallets, stacking every pallet in the same orientation helps support uneven weight and prevents collapse.
  • Height Limits: Keep empty pallet stacks to a safe height (often no more than 4–6 feet for manual stacking). Tall piles can become unstable. In rack systems, do not exceed rack or sprinkler clearance guidelines.
  • Stability: Use stacking guides, frames, or shrink wrap for very tall stacks or when handling aggressive forklift traffic. Pallet stacking frames or rack slot bins can prevent leaning and facilitate forklift entry.
• Racking:
• • When using pallet racking, ensure each pallet sits squarely on the beam support rails. Pallets should not overhang front or back beams. Uneven overhang concentrates weight on one beam and can cause failure.
  • Use wire mesh or solid decking between beams if loads have point weights (e.g. drum placed on only two boards) to distribute forces evenly.
  • Observe rack load capacities. Record the allowable weight per beam level and ensure pallet loads do not exceed it.
• Floor Stacking (If Needed):
• • Single Stack: Place pallets or pallet loads side by side on the floor without stacking on top. Use this only for heavy or bulky items where stacking is impractical.
  • Block Stacking: When double-stacking pallets on the floor, place them in tight blocks (no flue space). However, be mindful of fire codes: many regulations limit block stack heights (commonly under 15 feet for wood) and require access aisles.
  • Always keep 2–3 feet clear between separate stack blocks to allow airflow and forklift access.
• Layout Planning: Arrange aisles wide enough for forklifts and allow easy inspection of all stacks. Avoid storing pallets near heat sources or chemical storage, especially for wood. Designate separate zones for empty pallets versus loaded pallets; empty stacks are usually lower priority and shouldn’t block operations.
  

Common Mistakes That Reduce Pallet Lifespan

Avoid these costly errors:

• Overloading Pallets: Placing more weight on a pallet than it is rated for causes immediate or eventual failure. Wooden pallets may crack boards under excessive weight; plastic pallets can bow or crack unpredictably. Always know each pallet’s weight limit (both uniform distributed load and point load) and train staff to follow it.
• Uneven Loads: Putting heavy cargo all on one side or corner causes tilting or binding. This stresses the pallet asymmetrically, leading to twisting or one-sided failure. Balance heavy items across the pallet deck whenever possible.
• Stacking Too High or Leaning: Overly tall stacks of pallets (especially empty wood pallets) risk collapse. A collapse can ruin many pallets at once. Likewise, mixing a slightly warped pallet into a stack can propagate the lean. Remove any warped or damaged pallet rather than stacking it.
• Ignoring Pallet Damage: Continuing to use cracked or splintered pallets invites bigger accidents. A broken plank or loose nail can catch on a load or cause the pallet to break under load. Inspect pallets regularly and immediately remove or repair any that are compromised.
• Dragging and Dropping: Pushing pallets along the floor or dropping from height damages decks and runners. Forceful impact can break boards or shatter plastic. Every forklift operator should handle pallets gently.
• Improper Fork Entry: For example, using only two forks on a 4-way entry pallet or sticking forks too far through a thin plastic pallet. Both cause excessive stress on specific boards and can crack them.
• Floor Storage on Concrete: Wood pallets placed directly on concrete can absorb moisture and rot from the bottom. They also collect grime that hides damage. Always elevate wooden pallets on blocks or plastic spacers.
• Neglecting Maintenance: Letting dirt accumulate, not cleaning spills, or skipping repairs shortens pallet life. Even plastic pallets benefit from periodic washing to remove acids or sticky substances that degrade resin.
• Non-Uniform Stacks: Stacking different pallet types (wood with plastic, or mismatched sizes) can cause gaps, making stacks unstable. It also complicates handling. Keep stack groups homogeneous.

By monitoring these pitfalls and training staff to avoid them, pallet degradation is minimized. Regular audits of storage areas and handling operations can catch mistakes early.

Environmental Factors Affecting Pallet Longevity

Moisture and Humidity

• Wood: Absorbs water and high humidity, causing boards to swell, warp, or rot over time. Constant dampness (over 20% moisture content) will allow fungal decay. Keep wooden pallets dry – never store under leaking pipes or in unventilated damp corners.
• Plastic: Does not absorb water. Plastic pallets are immune to swelling or rot. They can even float briefly without damage. However, standing water can trap contaminants under pallets, so still keep storage surfaces clean.

Temperature

• High Heat: Can soften some plastics (especially if thin or recycled resin) causing sagging under loads. In extreme cases, it may weaken plastic welds or seams. Wood can dry out and crack in very hot, dry conditions. Where heat is a concern (near ovens, furnaces, or in outdoor sun), use heat-resistant pallets or provide shading.
• Cold: Very low temperatures make many plastics brittle. A plastic pallet might crack suddenly if hit when frozen. Wood is also more fragile when frozen, but typically splinters rather than shattering. Limit use of brittle pallets in extreme cold; store them indoors or in climate-controlled areas.

Sunlight and UV

UV radiation degrades plastics over months/years, causing discoloration and loss of tensile strength. Even UV-stabilized plastics will dull over time if unshielded. Wooden pallets fade in color from UV but maintain strength (unless they become extremely dry and brittle). Keep plastic pallets indoors or under cover to prolong life.

Pests and Mold

Wood is organic and attracts insects and mold if left damp. Termites or wood-boring beetles can infest stored pallets. Regularly inspect wooden pallet stacks for insect damage or webbing, and treat as needed. Plastic pallets do not have this issue.

Chemical Exposure

Wood will absorb spilled chemicals, potentially weakening fibers or causing hidden rot. Plastic resins may resist many chemicals better, but some solvents can attack certain plastics. Clean up spills quickly. In chemical plants, use chemically-compatible pallets (often HDPE) and segregate pallets by product type.

Vibration and Impact

Constant vibration from conveyor systems or nearby heavy machinery can create tiny cracks in pallets (material fatigue). Impacts from trucks or falling objects also damage pallets. Where vibration is heavy, use rubberized mats under pallet stacks or ensure pallets used are rated for dynamic shock loads.

Mechanical Stress and Fatigue

Every time a pallet is loaded, moved, or lifted, it undergoes stress. Over thousands of cycles, both wood and plastic exhibit fatigue:

• Wood Pallets: The nail and screw connections are stress points. Boards can split around nail holes, nails can loosen, and wood fibers can crush at high-pressure areas (like under forklift tine points). After repeated use, even correct loads can cause a gradual failure. Wood pallets also tend to wear out faster at the corners and stringer edges where forklifts make contact.
• Plastic Pallets: These often flex under load. Repeated bending leads to micro-cracks, especially at corners, entry holes, or where loads concentrate. Some plastic designs have engineered weak points (like breakaway bottom deck tabs) that fail in a controlled way to protect the rest of the pallet. Even a crack that doesn’t break immediately will compromise strength over time.

Strategies to Reduce Mechanical Wear:

• Rotate Pallet Stock: Don’t use the same pallets for the heaviest loads constantly. Cycle pallets through lighter use so wear is even.
• Avoid Excessive Moves: Consolidate moves when possible. Each forklift pick-and-place is one more stress cycle.
• Use Shock Absorbers: When lowering pallets, operators should decelerate gently. Some forklifts have cushioning systems; if not, manual control is key.
• Replace Hardware: For wood pallets, you may be able to pound nails back in or replace bent connectors. Tight, fresh fasteners improve strength.
• Retire Worn Pallets: Establish a criterion (e.g. number of broken boards, size of crack) beyond which a pallet is scrapped or recycled rather than repaired. Pushing a pallet past its fatigue point risks load failure.
  

Equipment Compatibility

Mismatches between pallets and material-handling equipment cause unnecessary damage:

• Forklifts: Ensure forks fit the pallet’s design. Standard (GMA) wood pallets are usually 40″×48″ with notches on two sides; but 4-way entry plastic pallets may require forks to enter under bottom deck boards. Using a 2-way entry fork on a 4-way pallet can break off deck boards. Always confirm the fork spacing and width suits the pallet style.
• Pallet Jacks and Stackers: Narrow jacks may not support wide stringer pallets. The jack’s wheels should not catch on deck boards. Likewise, hand stackers that lift the whole pallet need pallets with a flat bottom surface.
• Conveyor Systems: Live rollers or powered conveyors require pallets to have a solid, even bottom or skids. Some plastic pallets have cutouts or battens; these must align with conveyor rollers. If a pallet is too short or uneven, place plywood sheets on top to spread the weight on the belt/rollers.
• Automated Handling (AGVs, Robots): These systems often have strict dimensional tolerances. Use pallets certified for automation with consistent geometry. Test any new pallet model with the equipment before large-scale use.
• Cross-Docking and Mixing: If pallets move between different warehouse systems, agree on a standard. For instance, if loading from an aerial lift into a truck, the lift forks and truck docks should handle the pallet style. Incompatible interface (like trying to use a pallet jack on a pallet with very small bottom supports) will stress the pallet unpredictably.

Weight Distribution and Stacking Strategies

How you place products on a pallet and how you stack pallets also affects longevity:

• Even Load Distribution: Spread weight uniformly across the entire deck. A centered load avoids tipping. For heavy items, place them over the bottom deck boards rather than bridging two boards in the center unsupported.
• Load Center of Gravity: Heavier items should be at the bottom and toward the pallet’s center. This lowers the stack’s center of gravity and reduces bending on top boards.
• Alternating Layers (if applicable): When double-stacking pallets, cross-stack (place pallets perpendicular) every other layer to improve stability.
• Interlocking Stacks: For empty pallet stacks, rotating each pallet 90° relative to the one below can create a tighter, more stable stack. This only applies to empty pallets and takes time to arrange.
• Rack Considerations: In racking, loads should not extend over the edge of beams. If cargo hangs off a rack beam, it will lever and bend the pallet. If a load is too small to cover the span, use deck plates to fill the gap.
• Label Capacities: Clearly mark maximum weight on racks and on forklift data plates. Make sure all team members are aware of weight limits for equipment and pallets.
• Avoid Mixing Goods and Empty Pallets: A common mistake is stacking loaded pallets on top of empty pallet stacks (or vice versa) without noticing the increased height and changed weight profile. Always consider the full stack’s stability.

Pallet Maintenance and Inspection

A formal maintenance routine pays off:

• Regular Inspections: Schedule daily or weekly checks of pallet condition. Look at underdecks for unseen damage. Listen for loose boards or nails by gently tapping. Check plastic pallets for surface cracks, especially at corners and edges.
• Cleaning: Keep pallets free from debris and spills. For wood pallets, sweep off dirt and dry them if they get wet. For plastic pallets, periodic pressure washing with mild detergent will remove grime without damaging the polymer.
• Repairing Wood Pallets: Replace broken boards, reinforce cracked stringers with steel plates or new wood inserts, and tighten loose nails. Use compatible wood (similar thickness) for replacements. Proper repairs can extend a wooden pallet by 1–2 extra years of use.
• Plastic Pallet Care: Most plastic pallets cannot be repaired easily on-site. Some designs allow bonding with epoxy or using plastic welding kits for small cracks. For heavily used plastic fleets, consider having a vendor who can recondition or replace worn pallets.
• Pest Control: If any infestation is found on wood pallets, isolate and treat. Use heat or approved chemical treatments (if appropriate) to kill pests before returning pallets to service.
• Documentation: Keep logs of pallet repairs and retirements. Tracking which pallets fail and how often can reveal patterns (e.g. maybe one supplier’s pallets break more quickly, or a particular warehouse zone exposes pallets to damage). This data helps in choosing better pallets or changing procedures.

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Warehouse Layout and Racking Considerations

• Aisles and Access: Design aisles at least the minimum width for your forklifts (often 10–12 feet for standard counterbalance trucks). Wider aisles give more maneuvering room and reduce collision risk.
• Traffic Management: Ensure one-way or segregated flows for pedestrians and equipment. Signs reminding drivers to lower forks and watch for pallets can reinforce safe handling.
• Rack Loading Plan: Analyze your inventory’s weight and turnover. Reserve the strongest racks for the heaviest pallets. Put frequently accessed pallets at convenient heights.
• Empty Pallet Area: Have a designated spot for empty pallets, separate from loaded inventory. Stack empties neatly in that area. This keeps them from blocking operations and makes inspection easier.
• Environmental Controls: If your warehouse has areas of very high humidity or spills (like near docks or wash areas), avoid storing pallets directly there. Use sloped drains and good ventilation to keep pallet zones dry.
• Fire Safety: Although not the primary goal of extending pallet life, remember that wood pallets are combustible. Comply with any local codes on pallet stack heights, sprinkler spacing, and aisle widths to avoid hazards.