Pallet Types

There are several main types of pallets used in global supply chains. Each type offers different benefits in terms of durability, cost, weight, and specific use cases.

Entry Types: 2-Way vs 4-Way Entry

Before diving into specific pallet construction types, it's important to understand the entry design of pallets, which determines how forklifts can access them.

2-Way Entry Pallets

2-way entry pallets allow forklifts to insert forks from two opposite sides only. These are typically standard stringer pallets without notches.

4-Way Entry Pallets

4-way entry pallets allow forklifts to insert forks from all four sides of the pallet. This can be achieved through:

Notched Stringer Pallets: Stringers with cutouts (notches) that allow forks to enter from all sides.

Block Pallets: The block design inherently allows access from all four sides.

Pallet Construction Types

Stringer Pallets

Stringer pallets, also known as "runner pallets," consist of three or more parallel pieces of lumber (stringers) that support the top deck boards.

Characteristics:

• Three or more parallel support boards (stringers)
• Typically less expensive than block pallets
• Available in both 2-way (standard) and 4-way (notched) designs
• Widely used in North American markets
• Weight capacity typically ranges from 1,500 to 4,500 pounds
• Common in one-way shipping applications

Block Pallets

Block pallets use blocks of solid wood or compressed wood material at the corners and center points to support the deck boards, allowing 4-way entry.

Characteristics:

• Blocks at corners and central points instead of continuous stringers
• Inherent 4-way entry design (accessible from all sides)
• Greater stability than stringer pallets
• Higher load capacity (typically 3,000 to 5,500 pounds)
• Generally more durable but also more expensive
• Preferred in European markets and international shipping
• Compatible with automated handling systems

Nestable Pallets

Nestable pallets have a unique design that allows them to nest inside one another when empty, saving significant space during return transport.

Characteristics:

• Molded legs or runners that allow nesting when empty
• Typically made from plastic or pressed wood fiber
• Space-efficient for return shipping (can reduce space needs by up to 70%)
• Lighter weight than traditional wood designs
• Usually feature 4-way entry
• Lower load capacity than block or stringer designs
• Common in retail and grocery applications

Other Pallet Types

Double-Face Pallets

Double-face pallets have deck boards on both the top and bottom, providing greater stability and protection for the goods being transported.

Characteristics:

• Deck boards on both top and bottom
• Greater structural integrity than single-face designs
• Suitable for rack storage systems
• Higher cost due to additional materials
• Available in both stringer and block designs
• Heavier than single-face alternatives

Single-Face Pallets

Single-face pallets have deck boards only on the top surface, with the bottom supported directly by the stringers or blocks.

Characteristics:

• Deck boards only on the top surface
• Lighter weight than double-face pallets
• Lower cost to manufacture
• Less material usage (more environmentally friendly)
• Not suitable for some rack storage systems
• Commonly used for one-way shipping

Specialty Pallets

Beyond the standard types, there are numerous specialty pallets designed for specific industries or applications:

• Drum pallets: Designed with recessed areas to secure cylindrical containers
• Hygiene pallets: Seamless designs that can be easily cleaned and sanitized
• Display pallets: Designed for retail floor use with finished edges and surfaces
• Rackable pallets: Specifically engineered to span rack supports safely
• Heat-treated pallets: Treated to meet ISPM-15 requirements for international shipping
• Custom-size pallets: Built to non-standard dimensions for specialized cargo

Selection Guide

The right pallet type depends on several factors:

1. Load requirements: Weight, dimensions, and distribution of the load
2. Handling equipment: Types of forklifts and automated systems in use
3. Storage method: Floor stacking, rack storage, or automated systems
4. Supply chain characteristics: One-way or closed-loop
5. Regulatory requirements: Especially for international shipping
6. Cost considerations: Initial cost vs. reusability and lifespan
7. Environmental factors: Reusability, recyclability, and sustainability goals

Entry Type Selection Factors

When deciding between 2-way and 4-way entry pallets, consider:

1. Warehouse Space: 4-way entry pallets provide more flexibility in tight spaces
2. Loading/Unloading Methods: Some loading operations can only access pallets from specific directions
3. Automation Requirements: Many automated systems require 4-way entry
4. Cost Considerations: 2-way entry pallets generally cost less to manufacture
5. Structural Requirements: Solid stringers provide more structural integrity for very heavy loads

Specialized Pallet Types

Drum Pallets

Designed specifically for drum storage and transportation.

Display Pallets

Smaller pallets designed for retail displays and partial loads.

Hygiene Pallets

Designed to be easily cleaned and sanitized for food, pharmaceutical, and medical applications.

Rackable Pallets

Specifically designed to be safely used in racking systems.

Pallet Selection Guidelines

When selecting a pallet type, consider:

1. Entry Requirements: Whether 2-way or 4-way entry is needed
2. Load Requirements: Weight, dimensions, and distribution
3. Handling Equipment: The types of forklifts, pallet jacks, and automated systems that will interact with the pallet
4. Storage Conditions: Temperature, humidity, and exposure to elements
5. Transportation Method: Truck, rail, ship, or air
6. Reusability Needs: One-way or multiple use
7. Regulatory Requirements: Industry-specific or international shipping regulations
8. Cost Considerations: Initial cost vs. lifetime value