Pallet problems usually surface at the least convenient time: on the receiving dock, during order picking, at the palletizer or when a forklift operator is about to place a load in the rack. Is that broken pallet still usable? Can it be repaired? Does a repaired export pallet still comply with ISPM 15? And how much pallet overhang is too much?
Pallet Problems provides practical answers to common questions about pallet damage and repair, export pallets, load stability, storage, markings and safe reuse. The answers draw on industry standards, regulatory sources and more than three decades of reporting on pallets, reusable packaging and unit loads.
Use the topics below to find the pallet problem you are trying to solve.
Pallet Basics & Selection
What Is a Pallet?
A practical introduction to pallets, including how they work, common materials and designs, standard sizes, reusable pallet systems and the factors that influence pallet selection.
What Are the Different Types of Pallets?
Pallets can be classified by entry type, construction, material, size and intended use. Learn the differences between two-way and four-way, stringer and block, wood and plastic, reusable and expendable pallets, and where each type is commonly used.
What Is the Standard Pallet Size?
The standard pallet size in North America is 48×40 inches, but other dimensions are widely used by particular industries and in other parts of the world. Compare common North American, European and international pallet sizes, and learn why pallet dimensions matter.
Pallet Damage & Repair
Broken boards, damaged stringers and questionable repairs are everyday pallet problems. The first step is deciding whether the pallet should remain in service, be repaired or be removed from the usable pallet pool.
When Should a Wood Pallet Be Taken Out of Service?
A broken board doesn’t always mean a pallet has reached the end of its useful life, but some damage shouldn’t be ignored. Learn what to look for, including split stringers, broken blocks, missing deck boards, exposed fasteners, contamination, decay and other signs that a pallet should be removed from service.
Can a Broken Wood Pallet Be Repaired and Safely Reused?
Many damaged wood pallets can be repaired and returned to service. The question is whether the repair restores the pallet to the required specification and whether repairing it makes economic sense. Certification and proprietary pallet-pool requirements can complicate the decision.
Can a Damaged Plastic Pallet Be Repaired?
Some damaged plastic pallets can be repaired, particularly reusable designs with replaceable components or established repair procedures. Others should be removed from service and recycled. The pallet design, location of the damage and intended application all matter.
ISPM 15 & Export Pallets
International shipping adds another layer to pallet management. Solid wood packaging moving between countries may be subject to ISPM 15 phytosanitary requirements, while repairs, faded markings, pallet sourcing and even previous use can affect whether a pallet remains suitable for export.
Does a Repaired ISPM 15 Pallet Need to Be Heat Treated Again?
Not always, but the answer depends on where the repair takes place, how extensive it is and the certification program involved. Canada’s rules allow certain limited repairs within its authorized program without retreating the entire pallet, while current U.S. guidance requires repaired or remanufactured wood packaging to be treated again and remarked.
What If the IPPC/ISPM 15 Stamp on a Pallet Is Unreadable?
Years of forklift handling, weather and abrasion can leave an otherwise serviceable export pallet with a faded IPPC mark. ISPM 15 marks must be legible, and an unreadable mark can create a compliance problem. Don’t try to retrace or touch up an official certification mark yourself.
Should I Buy Used Heat-Treated Pallets for International Shipping?
Used HT pallets can be a legitimate and economical choice for international shipping. Age isn’t necessarily the issue. Pay attention to the IPPC mark, previous repairs, structural condition, contamination and the reliability of the pallet supplier.
What’s the Best Pallet for Export Shipping: Wood, Plastic or Presswood?
Heat-treated wood remains the workhorse of export shipping, but plastic and qualifying processed-wood pallets can avoid ISPM 15 requirements altogether. Cost, weight, load capacity, moisture exposure, handling systems and whether the pallet will be reused can all influence the choice.
Do Heat-Treated Pallets Expire?
No. ISPM 15 heat treatment doesn’t expire simply because a pallet gets older. But an older HT pallet still needs a legible mark, appropriate repair history, sound structural condition and freedom from pest or contamination concerns.
What Happens If My Export Pallets Fail ISPM 15 Inspection?
Noncompliant wood packaging can create a problem for the entire shipment. Depending on the destination and violation, a shipment may be held or refused entry, while authorities may require treatment, re-export, destruction or other safeguarding measures. Delays, additional costs and financial penalties may also follow.
Pallet Safety & Load Stability
A pallet can be perfectly sound and still be part of an unstable unit load. Pallet size, carton placement, load distribution, stretch wrapping, transportation forces and stacking practices all influence what happens between the palletizer and final delivery.
How Much Pallet Overhang Is Too Much?
Unintended pallet overhang can leave product unsupported while also increasing the effective footprint of the load. That can create problems in staging lanes, trailers, pallet racking, conveyors and automated handling systems.
Why Is My Pallet Load Leaning?
A leaning load can begin with a damaged pallet, uneven weight distribution, crushed cartons, an unstable pallet pattern or inadequate load containment. Where the lean begins often provides the best clue to what went wrong.
Why Do Pallet Loads Shift During Transportation?
Braking, cornering, vibration and impacts can expose weaknesses that aren’t apparent when a pallet is sitting on the warehouse floor. The pallet, load pattern, stretch wrap and trailer restraint all play a part in keeping the load together.
Should Cartons Overhang a Pallet or Be Set Back From the Edge?
Ideally, carton dimensions and the pallet footprint should be designed to work together. Overhang can leave critical carton structure unsupported, while excessive setback or underhang can waste pallet deck space and create other unit-load problems.
Can Loaded Pallets Be Double-Stacked?
Loaded pallets can be double-stacked when the lower load, packaging and pallets can carry the additional weight and the combined stack remains stable. Carton compression strength and load distribution can be just as important as pallet capacity.
How Many Pallets Fit in a Truck?
A 53-foot trailer typically holds 26 standard 48×40-inch pallets when straight-loaded, although different loading patterns can accommodate more. Learn how pallet size, orientation, overhang, weight and double-stacking affect trailer capacity.
Mold, Contamination & Pallet Storage
Wood pallets spend much of their working lives waiting for their next move. Moisture, weather exposure, poor airflow and improper stacking during that downtime can affect pallet condition, while storage practices also have implications for fire protection and workplace safety.
Why Are My Wood Pallets Getting Moldy?
Pallet mold usually starts with moisture. Wet lumber, rain, humidity, poor airflow and storage conditions can all contribute to mold growth, and an ISPM 15 heat-treatment mark does not mean that a pallet is mold resistant.
Can Moldy Wood Pallets Still Be Used?
Visible mold doesn’t necessarily mean that a pallet has lost its structural strength, but that doesn’t make every moldy pallet suitable for reuse. The decision depends on the condition of the wood, the extent of the mold and the requirements of the product and supply chain.
What’s the Best Way to Store Wood Pallets Outside?
Wood pallets can be stored outside, but good storage practices can reduce problems with moisture, mold, contamination and deterioration. Drainage, airflow, stack stability, fire separation, forklift access and emergency access should all be part of the storage plan.
How High Can Empty Pallets Be Stacked?
There isn’t one universal maximum height for every empty pallet stack. Pallet condition, stack stability, the storage surface, forklift handling and the facility’s fire-protection requirements all need to be considered when establishing a safe limit.
Used Pallets & Pallet Pools
Used pallets can be assets, liabilities or somebody else’s property. Pallet size, condition and local demand help determine whether an unwanted pallet has resale value, while rental and pooled pallets need to be kept out of the normal scrap and recycling stream.
How Do I Know Whether a Used Pallet Is Worth Money or Just Scrap?
A used pallet has value when there is a market for that particular size and style and the pallet is reusable or economically repairable. Standard sizes, condition, quantity, location and local demand can all make the difference between a pallet worth recovering and one destined for scrap.
What Should I Do With CHEP, PECO or iGPS Pallets That Arrive at My Business?
Set pooled pallets aside and arrange collection or return through the appropriate pallet pool. CHEP, PECO and iGPS pallets remain pool assets and shouldn’t be sold, dismantled, repaired or mixed into an ordinary pallet recycling stream simply because they arrived at your facility.
About the Pallet Problems Series
Reusable Packaging News has covered pallets, reusable packaging and unit-load handling for more than 20 years. The Pallet Problems series brings that reporting together with current industry standards and regulatory guidance to answer the practical questions that arise in warehouses, manufacturing plants, distribution centers, shipping departments and pallet yards.
We will continue adding answers as new questions arise. Have a pallet problem we haven’t covered? Send it to us. It may become a future Pallet Problems article.
Have a Pallet Problem We Haven’t Covered?
Have a question about pallet damage, repair, storage, ISPM 15, load stability, pallet pools or another pallet problem? Send it to us. We may answer your question directly or use it as the basis for a future Pallet Problems article.
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