Custom Dimensions
When off-the-shelf will not do. We build pallets to your exact specifications.
Request Custom Pallets
Describe your requirements and we will design the perfect pallet.
When You Need Custom
Most businesses can work with standard pallet sizes. But there are situations where a custom pallet is the right — or only — choice. If your product has unusual dimensions, extreme weight requirements, or needs to fit a specific racking or container system, custom is the way to go.
At Bakersfield Pallet Co., Garrett Caldwell and our production team have designed and built custom pallets for applications ranging from delicate aerospace components to 5,000-pound oilfield equipment. Our approach combines practical woodworking expertise with engineering principles to create pallets that are purpose-built for your exact application.
Our custom pallet service handles everything from design consultation to production. We can build pallets in any dimension, from any material, to any specification. Whether you need a single prototype or a recurring production run of thousands, our facility at 3240 Patton Way, Bakersfield, CA 93308 has the equipment, space, and skilled workforce to deliver.
Minimum orders for custom pallets are as low as 25 units, making custom viable even for low-volume specialty products. For larger recurring orders, we maintain dedicated jigs, templates, and production setups so your custom pallets are produced with the same speed and consistency as our standard sizes.
Custom Options
Any length x width combination from 18 inches to 120 inches on either axis. Custom heights from 3.5 inches (low-profile) to 12 inches (heavy-duty skid). Non-rectangular shapes available for specialized applications.
Softwood (pine, spruce, fir) for cost-effective applications. Hardwood (oak, maple) for heavy-duty and high-cycle applications. Plywood for full-deck requirements. Plastic and hybrid wood-plastic construction for washable and clean room environments.
2-way (stringer), 4-way (block or notched), or partial entry. Custom fork pocket sizes for non-standard forklifts and handling equipment. Crane lifting eye attachments for overhead handling.
Full deck (no gaps), partial deck (standard board spacing), or custom board spacing for airflow, drainage, or product retention. Top deck, bottom deck, or both can be customized independently.
Engineered for your specific static, dynamic, and racking load requirements. From 500 lbs (lightweight display) to 10,000+ lbs (heavy industrial skid). Load analysis available for critical applications.
Heat treatment (ISPM-15 for export). Kiln drying (for moisture-sensitive applications). No chemical treatments available for organic food applications. Paint, stain, or clear coat for display and branded pallets.
Cradles and saddles for cylindrical products. Bolt-down holes for product securing. Anti-slip surfaces for load stability. Branding (burned or printed logos). Nesting features for efficient empty pallet stacking.
Minimum Orders & Lead Times
Our custom pallet program is designed to be accessible to businesses of all sizes. Whether you need a small batch for a specialty project or thousands of units per month for ongoing production, we scale our process to match your needs.
Small Batch
25 - 99 pallets
Lead time: 7-10 business days | Per-unit pricing with setup fee
Ideal for prototyping, testing new products, or low-volume specialty applications. Setup fee covers jig fabrication and first-run calibration.
Standard Production
100 - 499 pallets
Lead time: 5-7 business days | Volume-adjusted per-unit pricing
Most common custom order size. Setup costs are amortized across the order, reducing per-unit cost. Jigs retained for reorders.
High Volume
500+ pallets
Lead time: 5-10 business days (depending on quantity) | Best per-unit pricing with annual contract options
Dedicated production runs with maintained jigs and templates. Standing order scheduling available for recurring needs. Annual contract pricing locks in rates.
Rush Orders
Any quantity
Lead time: 3-5 business days | Standard pricing plus rush surcharge
For time-sensitive custom orders. Oakley Thorne coordinates rush scheduling to fit custom orders into the production calendar on an expedited basis.
Recurring Orders
Per schedule
Lead time: Per standing schedule | Best pricing with volume commitment
Set it and forget it. We produce and deliver your custom pallets on a recurring schedule — weekly, bi-weekly, or monthly — matching your production consumption.
Prototype / Sample
1-5 pallets
Lead time: 5-7 business days | Prototype pricing
For complex designs that need testing before committing to production volume. Prototype cost is credited toward the first production order.
Design Considerations
Designing a custom pallet involves balancing multiple factors: product protection, handling efficiency, transportation constraints, cost, and durability. Our design team walks you through each of these considerations to ensure the final product meets every requirement of your application.
Product Dimensions & Geometry
The most fundamental factor in custom pallet design is the product itself. We need to understand the length, width, height, and shape of what will sit on the pallet. For products with irregular shapes — such as cylindrical tanks, tapered containers, or L-shaped equipment — the pallet may need custom features like cradles, notches, or raised edges to prevent movement.
Questions We Will Ask:
- What are the exact dimensions of your product or load?
- Is the product shape regular (rectangular) or irregular?
- Does the product have a flat bottom or does it need a cradle or saddle?
- Will multiple products be stacked on each pallet?
Weight & Load Distribution
Custom pallets must be engineered to handle the actual weight and distribution pattern of your load. A 3,000-pound load centered evenly across the pallet requires different construction than a 3,000-pound load concentrated at one end. We analyze where the weight sits and design stringer placement, board thickness, and fastener patterns accordingly.
Questions We Will Ask:
- What is the total weight of the loaded pallet?
- Is the weight distributed evenly or concentrated in specific areas?
- Will the load be dynamic (moved by forklift) or static (stored in place)?
- Will loaded pallets be stacked? If so, how many high?
Handling & Transportation Method
How the pallet will be moved determines the entry type, stringer orientation, and structural reinforcement needed. Forklifts, pallet jacks, cranes, and automated systems each interact with the pallet differently. The transport method — truck, rail, ocean container, or air freight — also affects design requirements.
Questions We Will Ask:
- What equipment will be used to move the pallet (forklift, pallet jack, crane, other)?
- Do you need 2-way or 4-way fork entry?
- Will the pallet go into racking? If so, what type and beam spacing?
- Will the pallet be shipped by truck, rail, ocean container, or air freight?
Storage Environment
Temperature, humidity, and exposure conditions affect material selection and treatment requirements. A pallet destined for frozen storage has very different requirements than one used outdoors in the Central Valley sun. We select wood species, moisture content, and treatment options based on the environment the pallet will operate in.
Questions We Will Ask:
- Will the pallet be stored indoors or outdoors?
- What is the temperature range (ambient, refrigerated, frozen)?
- Will the pallet be exposed to moisture, rain, or washdown processes?
- Are there any chemical exposure concerns (acids, solvents, oils)?
Reusability & Lifecycle
Is this a single-use pallet or will it make many trips? Single-use pallets can be built lighter and cheaper, while multi-use pallets need heavier construction and better fasteners to withstand repeated handling. For closed-loop systems where the pallet returns to the origin, we can optimize the design for maximum lifecycle at the best cost per trip.
Questions We Will Ask:
- Is this a one-way (single-use) or multi-trip pallet?
- If multi-trip, how many cycles do you need?
- Will the pallet be returned to you or discarded at the destination?
- Is end-of-life recycling value a consideration?
Regulatory & Customer Requirements
Export shipments require ISPM-15 compliance. Food contact requires clean, inspected wood. Certain customers mandate specific construction details. We review all applicable regulations and customer specifications before finalizing the design to ensure your custom pallet is compliant from day one.
Questions We Will Ask:
- Will this pallet be used for international shipments (ISPM-15)?
- Will the pallet contact food products (food-grade requirements)?
- Does your customer have specific pallet specifications?
- Are there any industry certifications that apply (SQF, BRC, etc.)?
Engineering Capabilities
Custom pallet design is more than choosing dimensions — it is engineering a structure to support a specific load under specific conditions. At Bakersfield Pallet Co., we bring both practical experience and analytical rigor to every custom project.
Our design process considers the wood species and grade (which determines strength properties), the stringer or block configuration (which determines how loads transfer to the floor or rack), the deck board thickness and spacing (which determines how evenly the load is distributed), and the fastener pattern (which determines how the components hold together under stress).
For critical applications — such as heavy industrial skids or pallets used in automated systems — we can provide load analysis documentation showing the expected deflection, stress distribution, and safety factors for your specific loading scenario. This documentation is valuable for quality assurance programs and customer audits.
Wren Castellano, our Sustainability Director, also reviews custom designs for material efficiency. We optimize board counts, stringer dimensions, and overall material usage to minimize waste without compromising performance. This approach reduces cost for you and environmental impact for everyone.
Our Production Capabilities
Sawing & Dimensioning
In-house sawing equipment cuts lumber to any specified dimension. We can produce custom-width and custom-thickness boards that are not available as standard lumber.
Notching & Routing
Custom notching for fork entry, product cradles, and banding channels. CNC-precision routing available for applications requiring tight tolerances.
Assembly
Pneumatic nailing stations configured for any pallet geometry. Dedicated assembly jigs maintain dimensional consistency across production runs of any size.
Heat Treatment
On-site heat treatment kiln for ISPM-15 compliance. Capacity for custom pallets of any dimension. Temperature monitoring and documentation for every charge.
Finishing
Sanding, planing, painting, staining, and branding capabilities for appearance-grade and display applications. All finishes are applied before delivery.
Quality Control
Dimensional verification, load testing (on request), and visual inspection for every custom order. Documented quality records available for customers with formal QA requirements.
Material Sourcing
Access to a wide range of wood species, grades, and treatments through our supplier network. Specialty materials (tropical hardwoods, certified sustainable wood, marine-grade plywood) available through sourcing partners.
Custom Pallet Process
From initial consultation to delivery, our custom pallet process is designed to be thorough yet efficient. Most custom orders are delivered within 5-10 business days from design approval. Here is a detailed breakdown of each step.
Consultation & Requirements Gathering
1-2 business days
We begin with a detailed conversation about your application. Oakley Thorne or another member of our team will discuss your product, handling environment, transportation method, regulatory requirements, and budget. For complex applications, we may visit your facility to observe the handling conditions firsthand.
Deliverable: Written requirements document summarizing all specifications and constraints.
Design & Engineering
1-3 business days
Our design team creates the pallet specification based on your requirements. For standard custom sizes (non-standard dimensions but conventional construction), this is typically a straightforward process. For engineered custom pallets with special features — cradles, reinforcement, fastening systems — we develop detailed design drawings for your review.
Deliverable: Design specification with dimensions, materials, construction details, capacity ratings, and cost estimate.
Prototype & Approval
2-3 business days (if needed)
For straightforward custom sizes, we may skip directly to production. For complex designs, we build a prototype for your evaluation. You can test-fit your product, verify handling compatibility, and confirm that all specifications meet your needs before committing to a full production run.
Deliverable: Prototype pallet for evaluation. Approval sign-off before production.
Production
3-7 business days (depending on quantity and complexity)
Once the design is approved, we schedule production. For recurring custom orders, we build and maintain dedicated jigs and templates that ensure consistency across every production run. Our facility at 3240 Patton Way, Bakersfield, CA 93308 has the capacity to produce custom pallets alongside our standard inventory without disrupting either.
Deliverable: Completed pallets built to approved specifications.
Quality Inspection & Treatment
1-2 business days
Every custom pallet undergoes dimensional verification and structural inspection before shipping. If ISPM-15 heat treatment is required, pallets go through our kiln with documented temperature monitoring. Food-grade applications receive additional cleanliness inspection.
Deliverable: Inspected and treated pallets with quality documentation.
Delivery & Ongoing Support
Scheduled per your requirements
Pallets are delivered to your facility on your schedule. For recurring orders, we set up a production and delivery cadence that keeps you supplied without the need to manage individual purchase orders. Your account manager monitors quality and coordinates any design refinements based on field performance.
Deliverable: Delivered pallets. Ongoing production schedule for recurring orders.
Example Custom Projects
The following case studies illustrate the range of custom pallet projects we have completed for Central Valley businesses. Each project demonstrates our ability to solve unique packaging and logistics challenges through purpose-built pallet design.
Solar Panel Shipping Crates
MOQ: 50 pallets per production runClient: Central Valley solar installer
Challenge:
Standard 48x40 pallets did not match the 82-inch length of residential solar panels. Panels shipped on oversized standard pallets wasted truck space and required additional securing.
Solution:
Designed a custom 82" x 42" pallet with lightweight softwood construction to minimize shipping weight. Full top deck prevents panel flexion during transport. Integrated banding notches in the stringers for secure strapping without board damage.
HVAC Compressor Bases
MOQ: 25 pallets per production runClient: Regional HVAC manufacturer
Challenge:
Heavy compressor units (700-1,200 lbs each) required pallets with concentrated load support. Standard pallets deflected under the point-loaded weight, causing instability during shipping and storage.
Solution:
Engineered a 60" x 48" heavy-duty pallet with five hardwood stringers and full 3/4-inch deck boards. Added a center support plate under the primary bearing point. Integrated bolt-down holes for securing the compressor to the pallet with through-bolts.
Agricultural Bin Platforms
MOQ: 100 pallets per production runClient: Kern County tree fruit grower
Challenge:
Standard pallets were too small for the grower's custom harvest bins and too weak for the 1,400-pound filled weight. Bins were being placed directly on the ground, making forklift handling difficult and damaging bin floors.
Solution:
Custom 52" x 48" heavy-duty pallet with reinforced stringer spacing matched to the bin footprint. Runner boards on the top deck surface guide the bin into position and prevent sliding during transport. Oversized fork entry accommodates the wider forks used on agricultural forklifts.
Wine Barrel Cradle Pallets
MOQ: 50 pallets per production runClient: Paso Robles winery with Bakersfield distribution
Challenge:
Standard flat pallets cannot safely hold cylindrical wine barrels. Barrels were being stored on makeshift racks, creating safety hazards and inefficient use of warehouse space.
Solution:
Designed a 48" x 40" pallet with integrated V-saddle cradles that hold wine barrels securely in place. Saddle depth accommodates standard Bordeaux barrels (225L/59 gal) and can be adapted for Burgundy barrels. Stackable design allows two barrel pallets to be stacked for vertical storage.
Aerospace Component Shipping
MOQ: 25 pallets per production runClient: Defense contractor in Kern County
Challenge:
Sensitive aerospace components required pallets with precise dimensional tolerances, zero contamination risk, and compatibility with clean room receiving procedures. Standard commercial pallets did not meet the cleanliness or tolerance requirements.
Solution:
Custom 36" x 30" precision pallet built from kiln-dried, planed hardwood with sanded surfaces. All fasteners are stainless steel and countersunk below the surface. Pallets are individually wrapped in clean poly bags before delivery. Each pallet is measured and tolerance-verified with documented quality records.
Oversized Industrial Equipment Skids
MOQ: 10 skids per production runClient: Oilfield equipment manufacturer
Challenge:
Large oilfield pumps and motors (2,000-5,000 lbs) required oversized shipping platforms that standard pallets could not provide. Equipment footprints ranged from 72" to 120" in length.
Solution:
Engineered a family of heavy-duty skids in three standard lengths (72", 96", and 120") with 48" width. All-hardwood construction with laminated 6x6 runners. Steel reinforcement plates at critical stress points. Lifting eye bolt attachment points for crane handling.
Material Selection Guide for Custom Pallets
The right material for your custom pallet depends on load weight, handling conditions, environmental exposure, and budget. Below is a comparison of the most common materials we use in custom pallet construction.
Southern Yellow Pine (SYP)
Best for: General purpose custom pallets. Good balance of strength and cost. Most common wood for custom pallet construction in our region.
Limitations: Susceptible to moisture and mold in wet environments. Moderate durability for multi-trip use.
Spruce-Pine-Fir (SPF)
Best for: Lightweight and export pallets. Lower cost than SYP with acceptable strength for moderate loads. Good availability.
Limitations: Lower strength than SYP or hardwoods. Not recommended for heavy-duty applications above 2,500 lbs dynamic.
Oak (Red/White)
Best for: Heavy-duty industrial pallets and skids. Maximum strength and durability. Multi-trip pallets that need to withstand hundreds of handling cycles.
Limitations: Heavy (increases shipping cost). Expensive. Can be difficult to nail without pre-drilling for some fastener configurations.
Maple
Best for: Heavy-duty pallets requiring excellent surface hardness. Resists denting and surface damage from product contact. Good for display applications.
Limitations: Cost premium over softwoods. Heavier than pine alternatives. Limited availability in some regions.
Plywood (CDX or Marine)
Best for: Full-deck applications. Excellent for preventing product sag between boards. Smooth surface for bag and sack loads. Marine grade for wet environments.
Limitations: Not suitable for stringer construction. Higher material cost than sawn lumber. Moisture damage in non-marine grades.
HDPE Plastic
Best for: Washable, clean room, and food processing environments. Consistent dimensions throughout lifespan. Immune to moisture, mold, and insects.
Limitations: Highest initial cost. Not repairable — must be replaced when damaged. Heavier than wood for equivalent size.
Ready to Start Your Custom Pallet Project?
Whether you have detailed specifications or just a problem that needs solving, Garrett Caldwell and the team at Bakersfield Pallet Co. are ready to design the perfect pallet for your application. Minimum orders start at just 25 units.
Typical lead time: 5-10 business days from design approval