Composite Pallets
The innovation frontier of pallet technology. Engineered materials designed for specific challenges.
Bakersfield Pallet Co. carries a growing selection of composite pallet options for businesses that need something beyond traditional wood or plastic. From presswood export pallets to corrugated air freight solutions and hybrid wood-plastic designs, our composite inventory at 3240 Patton Way, Bakersfield, CA 93308 covers the full spectrum of engineered pallet solutions.
Explore Composite Options
Tell us your requirements and we will recommend the right solution.
What Are Composite Pallets?
Composite pallets are manufactured from engineered materials — including pressed wood fiber, recycled plastics, corrugated materials, and hybrid constructions. They are designed to solve specific problems that traditional wood or plastic pallets cannot address alone.
Common composite pallet types include presswood pallets (made from compressed wood fiber), corrugated pallets (for lightweight shipping), and wood-plastic hybrids that combine structural elements of both materials.
These pallets are particularly popular for one-way export shipping, lightweight applications, and situations where traditional pallets are impractical. The composite pallet market has grown significantly as businesses look for ways to reduce shipping weight, comply with international regulations, and minimize environmental impact.
Our Sustainability Director, Wren Castellano, has been instrumental in expanding our composite pallet offerings. Many of our composite products are manufactured from 100% recycled content — including post-industrial wood waste and post-consumer plastic — making them an excellent choice for companies with sustainability targets.
The key innovation behind composite pallets is that they can be engineered to precise specifications. Unlike natural wood, which varies in density, moisture, and grain structure, composite materials are manufactured under controlled conditions to deliver consistent, predictable performance in every pallet.
Key Advantages
Up to 70% lighter than hardwood pallets, reducing shipping costs significantly. A presswood 48x40 pallet weighs just 18 to 22 lbs, compared to 40+ lbs for a standard wood pallet.
Processed materials do not require heat treatment for international shipping. Presswood pallets undergo temperatures exceeding 200°C during manufacturing, far above the 56°C ISPM-15 threshold. Corrugated pallets contain no solid wood at all.
Manufactured to precise tolerances with no natural variations like knots or grain direction. Every pallet in a batch is dimensionally identical, which is critical for automated handling systems and consistent stacking.
Many composite pallets can nest when empty, saving up to 60% warehouse space. Presswood pallets with molded feet are particularly efficient for return logistics and storage.
At end of life, composite materials can be recycled into new products or energy. Presswood can be composted or chipped for mulch. Corrugated pallets are recyclable with standard cardboard. Hybrids can be separated and recycled by material type.
Most composite pallets are manufactured as single-piece molded units with no nails, screws, or staples. This eliminates the risk of loose fasteners damaging products, conveyor belts, or worker hands.
Presswood pallets are treated with moisture-resistant resins during manufacturing. They absorb significantly less moisture than raw wood and maintain structural integrity in humid or wet conditions.
When factoring in the cost of heat treatment, fumigation documentation, and potential customs delays, composite pallets often cost less than ISPM-15 compliant wood pallets for international shipping.
Composite Pallet Types in Detail
We carry three primary types of composite pallets, each engineered for specific use cases. Below is a detailed breakdown of each type, including specifications, manufacturing process, and recommended applications.
Presswood Pallets
Compressed wood fiber — strong, moldable, and ISPM-15 exempt
Manufacturing Process
Presswood pallets are manufactured by collecting post-industrial wood waste — sawdust, wood chips, shavings, and off-cuts — and grinding them into fine fibers. These fibers are blended with a thermosetting resin (typically urea-formaldehyde or phenol-formaldehyde) and pressed under extreme heat (over 200°C / 392°F) and pressure (up to 1,500 PSI) in a hydraulic mold. The result is a dense, uniform board that is shaped into a pallet with integrated feet or runners during the molding process.
Because the manufacturing process subjects the wood fibers to temperatures far exceeding the ISPM-15 threshold of 56°C, presswood pallets are automatically exempt from international phytosanitary regulations. No additional heat treatment or fumigation is required, and no HT stamp is needed — though they do carry the appropriate processed wood material (PWM) marking.
Material Composition
Typical composition is 85–90% recycled wood fiber and 10–15% thermosetting resin binder. The resin creates a moisture barrier and provides structural cohesion. Some manufacturers add wax or other water-resistant additives for applications in humid environments. The finished material has a density of approximately 40–45 lbs per cubic foot, which is denser than most natural woods.
Specifications
Best Applications
Corrugated Pallets
Lightweight cardboard construction for single-use and air freight
Manufacturing Process
Corrugated pallets are manufactured from multiple layers of heavy-duty corrugated cardboard, laminated together and shaped into a pallet structure. The corrugation pattern provides surprising strength through its column-like flute structure — the same principle that makes a cardboard box strong despite being made from thin paper.
The manufacturing process begins with heavy-weight containerboard (typically 275 to 500 lb test) that is corrugated into triple-wall or honeycomb configurations. The layers are glued together with moisture-resistant adhesive and die-cut into the pallet shape. Legs or runners are formed by folding and laminating additional corrugated sections.
Some corrugated pallets are treated with water-resistant coatings or wax impregnation to improve their performance in humid environments. However, corrugated pallets are fundamentally a dry-environment product and are not suitable for outdoor storage or wet conditions.
Material Composition
100% paper-based product, typically manufactured from recycled containerboard. The corrugated structure uses a combination of linerboard (flat outer layers) and medium (the fluted inner layer). Triple-wall construction provides the strength needed for pallet applications. The finished product is 100% recyclable in the standard cardboard waste stream and is biodegradable.
Specifications
Best Applications
Wood-Plastic Hybrid Pallets
Combines wood stringers with recycled plastic decking for durability and longevity
Manufacturing Process
Hybrid pallets combine the structural strength of wood stringers or blocks with the durability and moisture resistance of recycled plastic deck boards. The plastic components are typically manufactured by melting post-consumer or post-industrial plastic (HDPE, PP, or mixed plastics) and extruding or injection-molding them into deck board shapes that match standard wood pallet dimensions.
The wood stringers provide the primary structural support and are compatible with standard nailing equipment, while the plastic deck boards provide a durable, moisture-resistant, and splinter-free surface. The two materials are assembled using standard pallet nailing equipment, screws, or specialized fastening systems.
The result is a pallet that has significantly greater longevity than an all-wood pallet. The plastic deck boards do not crack, split, or absorb moisture, which are the three most common failure modes for wood pallet deck boards. The wood stringers provide the load-bearing strength and are easily replaced if damaged, extending the overall pallet lifespan even further.
Material Composition
Hybrid pallets typically use Southern Yellow Pine (SYP) or mixed hardwood stringers combined with recycled HDPE or mixed-plastic deck boards. The plastic deck boards are manufactured to match standard lumber dimensions (typically 1" x 4" or 1" x 6" nominal) so they can be used as direct replacements for wood boards. Some hybrid designs also incorporate recycled plastic blocks or runners.
Specifications
Best Applications
Strength Testing & Performance Data
Composite pallets undergo rigorous testing during and after manufacturing to ensure they meet published load capacity and durability specifications. Our Operations Manager, Oakley Thorne, verifies that every batch of composite pallets we receive from our manufacturing partners meets the performance standards we promise to our customers.
The primary testing methods used for composite pallets follow ASTM D1185 (Standard Test Methods for Pallets and Related Structures Employed in Materials Handling and Shipping). These tests evaluate compression strength, flexure (bending), impact resistance, and corner/edge drop performance.
Presswood pallets are additionally tested for moisture uptake (ASTM D1037), since their wood-fiber composition makes them more susceptible to moisture than plastic or corrugated alternatives. Our presswood products maintain less than 8% moisture uptake by weight after 24-hour submersion testing.
Corrugated pallets are tested for edge crush strength (ECT) and burst strength using standard containerboard testing protocols. We require our corrugated pallet suppliers to provide certificates of analysis (COA) for each production run documenting these test results.
Testing Standards
Certifications We Verify
Moisture Resistance Comparison
Moisture is the number one enemy of pallets in transit and storage. Here is how each composite type performs compared to traditional wood in moisture exposure scenarios.
Presswood
Resin binder provides moisture barrier. Performs well in covered transit and warehousing. Not recommended for continuous outdoor exposure or direct water contact.
Corrugated
Paper-based construction absorbs moisture readily. Wax coating helps but does not provide full protection. Strictly for dry environments only.
Hybrid (Plastic Deck)
Plastic deck boards are impervious to moisture. Wood stringers may absorb some moisture but are protected by the plastic deck. Best composite moisture performance.
Raw Wood (Reference)
Untreated wood absorbs moisture along grain. Causes swelling, weight gain, weakening, and potential mold growth. Kiln-drying and coating improve but do not eliminate absorption.
Composite Pallets: Pros & Cons
No pallet type is perfect for every application. Here is an honest assessment of where composite pallets excel and where wood or plastic may be the better choice.
Advantages Over Wood & Plastic
Presswood and corrugated pallets are 40–70% lighter than wood, directly reducing freight costs. For air freight, every pound matters — a corrugated pallet at 10 lbs vs. a wood pallet at 45 lbs can save significant per-shipment costs.
Eliminates the cost, time, and logistical complexity of heat treatment and fumigation for international shipping. No scheduling, no additional per-pallet fees, no documentation risk.
Molded composite pallets have tighter dimensional tolerances than natural wood, which can vary with moisture, grain, and cutting accuracy. Critical for automated handling systems.
Single-piece molded composites (presswood, corrugated) have zero nails, screws, or staples. Eliminates product damage from loose fasteners and reduces worker injury risk.
Made from recycled content, fully recyclable at end of life, and often compostable (presswood, corrugated). Strong sustainability story for ESG reporting.
Presswood and corrugated pallets cost a fraction of plastic pallets while providing similar weight advantages and ISPM-15 exemption for one-way export applications.
Limitations to Consider
Corrugated pallets are typically single-use. Presswood pallets may last 3–10 trips. For multi-trip closed-loop systems, wood or plastic pallets offer better per-trip economics.
Unlike wood pallets where individual boards and stringers can be replaced, composite pallets cannot be repaired. A damaged presswood or corrugated pallet is recycled, not fixed.
Corrugated pallets have the lowest load capacity of any pallet type. They are not suitable for heavy loads, racking, or applications requiring more than 2,500 lbs dynamic capacity.
Corrugated pallets lose significant structural strength when wet. They must be stored indoors and are not suitable for outdoor loading docks, cold storage, or any environment with condensation.
Composite pallets are typically available in standard sizes only (primarily 48x40). Custom sizes may require minimum order quantities and lead times that are longer than custom wood pallets.
Most presswood and corrugated pallets are not rated for racking applications. Only hybrid wood-plastic designs and specific high-end presswood models are rackable.
Composite Pallet Applications by Industry
Composite pallets excel in specific niches. Here are the industries and use cases where our customers most commonly choose composite over wood or plastic.
International Export
Recommended: Presswood
The single largest market for composite pallets. Presswood pallets eliminate ISPM-15 hassles, reduce shipping weight, and are cost-effective for one-way international shipments. Used heavily by manufacturers shipping to Europe, Asia, and South America from Bakersfield and the Central Valley.
Air Freight & Courier
Recommended: Corrugated
Air freight charges are based on weight, making corrugated pallets at 8–15 lbs dramatically more cost-effective than wood at 40+ lbs. Used for high-value, time-sensitive shipments where every pound directly impacts freight cost.
Electronics & Technology
Recommended: Presswood or Corrugated
Zero-fastener construction eliminates the risk of nail damage to sensitive electronics. Consistent, clean surfaces protect product packaging. Lightweight designs reduce overall shipment weight for cost-sensitive tech logistics.
Pharmaceutical
Recommended: Presswood
Clean, consistent, and ISPM-15 exempt. Presswood pallets meet the hygiene and regulatory requirements of pharmaceutical distribution while providing significant weight savings over traditional wood.
Trade Shows & Events
Recommended: Corrugated or Presswood
Lightweight for easy manual handling at event venues. Can be recycled or discarded at the destination rather than returned. Low cost makes them practical for one-time event logistics.
Agriculture (Export)
Recommended: Presswood
The Central Valley produces billions of dollars in agricultural products destined for international markets. Presswood pallets provide ISPM-15 compliance without heat treatment, critical for time-sensitive produce shipping schedules.
Outdoor & Wet Environments
Recommended: Hybrid (Wood-Plastic)
Hybrid pallets with plastic deck boards resist moisture, weathering, and UV degradation that would destroy standard wood pallets in outdoor storage. The wood stringers provide structural strength while the plastic surface handles the elements.
Food Distribution
Recommended: Hybrid (Wood-Plastic)
The plastic deck surface is non-porous, easy to clean, and does not harbor bacteria. Combined with the cost advantages of wood structural components, hybrid pallets provide a practical middle ground between all-wood and all-plastic.
Military & Government
Recommended: Presswood
Government and military logistics operations increasingly specify composite pallets for international deployments. Weight savings reduce airlift costs, and ISPM-15 exemption simplifies customs procedures across multiple countries.
Composite Pallet Pricing Guide
Composite pallet pricing varies by type, size, and order volume. Below are approximate price ranges for our standard offerings. Volume discounts are available for orders over 100 units.
Presswood 48x40 — Standard
Per pallet, 50+ units
Presswood 48x40 — Heavy Duty
Per pallet, 50+ units
Presswood 48x48 — Chemical/Drum
Per pallet, 50+ units
Corrugated 48x40 — Standard
Per pallet, 100+ units
Corrugated 48x40 — Heavy Duty (Triple Wall)
Per pallet, 100+ units
Hybrid Wood-Plastic 48x40 — Standard
Per pallet, 25+ units
Hybrid Wood-Plastic 48x40 — Heavy Duty
Per pallet, 25+ units
Pricing is approximate and subject to raw material costs and availability. Contact our team for a firm quote based on your specific composite pallet requirements and volume.