Custom Pallets Built to Your Exact Specifications
When off-the-shelf pallets do not fit your product, your racking, or your workflow, we design and manufacture custom solutions from scratch. Any size, any material, any treatment -- engineered specifically for your application.
From Concept to Delivery in 5 Steps
Our custom pallet process is designed to get the design right the first time. We invest the time upfront in understanding your needs so production runs smoothly and the finished product performs exactly as expected.
Consultation & Requirements
We start with a detailed conversation about your product, load characteristics, handling equipment, storage method, and shipping workflow. We need to understand the full picture -- including how many pallets you need, how often, and where they are going -- to design the right solution.
Design & Engineering
Our team creates a detailed pallet specification that accounts for load distribution, deck board spacing, stringer or block placement, and overall dimensions. For complex or heavy applications, we use load analysis to ensure the pallet can handle the stress without failure.
Prototype & Approval
Before we commit to full production, we build a small batch of prototypes for you to test in your actual workflow. This step catches any issues with fit, handling, or compatibility before they become expensive problems at scale. We iterate on the design until it is exactly right.
Production & Treatment
Once the design is approved, we move into full production at our Romeoville facility. Depending on your requirements, pallets can be heat-treated to ISPM-15 standards, fumigated, notched for four-way entry, painted, branded, or treated with preservatives for outdoor use.
Delivery & Ongoing Supply
We deliver finished pallets directly to your dock on your schedule. For ongoing programs, we set up a recurring production and delivery cadence so you never run short. We also keep your design on file for fast reorder turnaround -- most repeat orders ship within 48 hours.
Treatments, Finishes & Customizations
Beyond basic dimensions, we offer a range of treatments and features that tailor each pallet to its intended use environment and regulatory requirements.
Heat Treatment (HT / ISPM-15)
International Phytosanitary Measure 15 requires all wood packaging materials used in international trade to be heat-treated to a core temperature of 56C for 30 minutes. We operate an APHIS-approved heat treatment chamber and stamp every treated pallet with the IPPC certification mark.
Notching for 4-Way Entry
Standard stringer pallets allow forklift entry from only two sides. By cutting notches into the stringers, we enable partial four-way entry so forklifts can access the pallet from any direction. This is essential for tight warehouse aisles and cross-docking operations.
Custom Painting & Branding
Color-code your pallets for easy identification in mixed-inventory environments. We can paint pallets in any color, stencil your company logo, or apply color-coded markings to differentiate product lines, customers, or return-pool pallets.
Preservative Treatment
For pallets that will be stored outdoors or exposed to moisture, we offer preservative treatments that protect against rot, fungal growth, and insect damage. This extends the useful life of the pallet from 2-3 years to 5-7 years in harsh conditions.
Reinforced Construction
Heavy loads demand heavier construction. We can add extra stringers, thicker deck boards, hardwood components, metal corner brackets, or plywood overlay decks to increase the load capacity well beyond standard pallet ratings.
Ventilated & Open Deck Designs
Products that need airflow -- like fresh produce, flowers, or items going through cooling tunnels -- benefit from wide-spaced deck boards or slatted designs that maximize air circulation while maintaining structural support.
Choose the Right Lumber
Softwood (Pine, Spruce, Fir)
Softwood is the most common and cost-effective material for pallet construction. It is lighter than hardwood, easy to work with, and readily available in bulk quantities. Southern Yellow Pine is the most popular species due to its excellent strength-to-weight ratio and abundance.
- Lower cost per board foot
- Lighter weight for shipping savings
- Easy to nail and repair
- Widely available year-round
- Good for medium-duty applications
Hardwood (Oak, Maple, Birch)
Hardwood pallets are heavier and more expensive but deliver significantly higher load capacities and longer service life. Oak is the most common choice for heavy-duty pallets, while maple offers an excellent strength-to-weight ratio for demanding applications.
- Superior load-bearing capacity
- Longer lifespan under stress
- Better nail-holding strength
- More resistant to impact damage
- Required for some heavy industrial uses
When Standard Pallets Are Not Enough
Custom pallets solve problems that off-the-shelf products cannot. Here are the most common scenarios where our customers benefit from a tailored approach.
Oversized Machinery & Equipment
Manufacturers of heavy equipment, HVAC systems, generators, and industrial machinery often need pallets that exceed standard dimensions. We build pallets up to 8 feet wide and 12 feet long with load capacities exceeding 10,000 lbs.
Odd-Size Consumer Products
Furniture, appliances, mattresses, and large-format electronics often do not fit standard 48x40 pallets efficiently. A custom pallet sized to your product eliminates wasted trailer space and reduces shipping costs per unit.
Export & International Shipping
Different countries use different standard pallet sizes. European importers expect EUR/EPAL 1200x800mm pallets, while Australian standards call for 1165x1165mm. We build to any international standard and certify for ISPM-15 compliance.
Automated Systems & Robotics
Automated guided vehicles (AGVs), robotic palletizers, and AS/RS systems require pallets with extremely tight dimensional tolerances. We build to tolerances of plus or minus 1/8 inch to ensure flawless performance in automated environments.
Display & Retail Pallets
Quarter-pallet and half-pallet display units need to look clean on the retail floor while supporting product weight and fitting standard shelf configurations. We build display pallets with sanded surfaces and cosmetic-grade lumber.
Reusable Pool Programs
Companies that ship to the same destinations repeatedly can save significantly with a custom reusable pallet program. We design pallets optimized for your specific loop, track inventory, and provide repair and replacement services.
Let's Design Your Perfect Pallet
Send us your product dimensions, weight, and any special requirements. We will come back with a custom pallet design, prototype timeline, and volume pricing -- typically within 24 hours.