Standard pallet sizes exist because they work for the majority of products and supply chains. But "majority" isn't "all." If your product has unusual dimensions, exceptional weight, or specific handling requirements, a custom pallet may be the right solution.
Common situations where custom pallets make sense include oversized machinery or equipment that overhangs standard pallets, heavy products that exceed standard pallet weight ratings, oddly shaped items that don't nest well on rectangular pallets, and products with specific regulatory requirements for packaging.
The custom pallet design process starts with understanding your product. What are the dimensions and weight? How will it be loaded and unloaded? What's the shipping method (truck, rail, air, ocean)? Will the pallet be reused or is it one-way? Are there handling requirements (forklift entry, crane lifting, hand-carry)?
We design custom pallets using standard lumber dimensions when possible — this keeps material costs down while achieving the required specifications. For unusual requirements, we can incorporate features like reinforced stringers for heavy loads, notched corners for strapping, integrated skids for ramp loading, or partial deck board spacing for ventilation.
Cost for custom pallets depends on complexity and volume. Simple size modifications to standard designs cost marginally more than standard pallets. Complex engineered solutions with specialized hardware or unusual lumber requirements cost more but are often less expensive than the alternative — which is usually shipping damage or wasted space.
We keep detailed specifications for every custom pallet we've built, so reordering is fast and consistent. If your custom pallet need is recurring, we can maintain a standing inventory ready for on-demand delivery.
If you have a product that doesn't fit the standard pallet mold, bring us the challenge. We've designed pallets for everything from agricultural equipment to solar panels to custom machinery. Our design process is free — we only charge for the pallets we build.
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