How to Choose Plastic Pallets?

A Complete Purchasing Guide: From Structure and Load Capacity to Material Specifications
Plastic pallets may look similar, but differences in their bottom structure (e.g., nine-legged or grid-like), material (PP or HDPE), and whether the load capacity listed on the specification sheet is static or rack load capacity directly affect their lifespan and operational safety. Focusing solely on price before purchasing can easily lead to overlooking crucial specifications.

This guide, compiled by Shin Tai Plastics Industry, clearly explains the details to consider when selecting plastic pallets, covering everything from on-site equipment and load capacity definitions to material structure and the specific needs of different industries.

I. Before placing an order, confirm these eight things:

Before requesting a quote, it's recommended to gather the following information so the supplier can accurately recommend the model:

1. Cargo dimensions and maximum weight

2. Expected pallet size

3. On-site use: forklift, manual pallet trolley, or electric pallet trolley

4. Required: two-way or four-way forklift entry

5. Pallet placement: ground, stacking, racking, or automated storage and retrieval system

6. Operating environment: ambient temperature, frozen, outdoor, food processing plant, or chemical plant

7. Required: anti-slip features, steel pipe reinforcement, special colors, or company logo

8. Required: RFID tracking for pallets

Even a single difference in these conditions can dictate the suitable model. Plastic pallets are not suitable for selection based solely on unit price.

II. Consider the structure first: On-site equipment determines which pallet type is suitable. Choosing pallets shouldn't start with weight capacity, but rather with confirming the on-site material handling equipment. The pallets that can be inserted by a manual hydraulic pallet trolley and a forklift may not be the same. Choosing the wrong type and discovering it won't fit on-site can cause significant problems.

Nine-leg type: Nine legs at the bottom allow empty pallets to be stacked together, saving space. Lightweight and relatively inexpensive, it can generally be used with both manual hydraulic pallets and forklifts. The disadvantage is a lower load capacity, making it more suitable for single-use export or handling lighter goods.

Three-line type: Three longitudinal supports at the bottom, shaped like the Chinese character "川" (river). It can be inserted by both forklifts and manual hydraulic pallets, and is relatively stable over automated conveyor belts, less prone to derailment. The disadvantage is that empty pallets cannot be stacked, taking up more space.

Two-line type: The most complete bottom support and highest durability, suitable for stacking two layers of goods without easily deforming the lower layer. However, note that most manual hydraulic pallets cannot be inserted—the small wheels will get stuck on the bottom crossbars when raised, and forcibly pulling may even tear the pallet structure. These pallets usually require a forklift for operation.

Double-sided type: The structure is identical on both sides; if one side is damaged, it can still be used by flipping it over. Primarily used in heavy industry or for high-bay racking to hold heavy items, but requires a dedicated double-sided forklift.

Flat type and mesh type: Flat types are easier to clean, suitable for hygiene-conscious environments like food and pharmaceuticals; mesh types are lighter and drain quickly, sufficient for general logistics. When choosing, also consider ease of cleaning, slip resistance, and water retention.

III. The "Three Load Capacities" on the Specification Sheet Have Completely Different Meanings

Many people see "4-ton load capacity" on the specification sheet and place an order directly, only to find the pallet breaking during handling—because the load capacity figure actually represents three different scenarios, and confusing them can easily lead to accidents.

Static Load: The weight the pallet can withstand when laid flat on the ground and goods are stacked on top and stationary. This number usually appears the highest, but it cannot be used to assess handling or shelving conditions.

Dynamic Load: The weight the forklift can withstand when the entire pallet is lifted and moved; this is the indicator to consider in actual handling operations.

Shelf Load Capacity: This refers to the weight a pallet can withstand when placed on a high-bay rack with only end supports and the middle suspended. If the warehouse is to use this racking, it's essential to confirm with the manufacturer whether steel reinforcement pipes can be added. Plastic pallets without steel reinforcement are likely to sag in the middle over time.

The actual safe load capacity is also affected by factors such as the even distribution of goods, the flatness of the bottom, impacts during handling, operating temperature, the distance between rack beams, and whether the pallet itself is aged or cracked. Before using it on racking or automated storage systems, it's best to confirm the testing conditions directly with the manufacturer.

IV. Material Selection: HDPE, PP, Virgin Material, and Recycled Material

HDPE (High-Density Polyethylene): Good toughness and impact resistance; it doesn't easily become brittle even in a -30°C freezer. Commonly used in cold chain logistics, low-temperature storage, and environments with high turnover.

PP (Polypropylene): Good rigidity and heat resistance; the material is relatively hard and not easily deformed. Suitable for general industrial storage, where structural support is required, or for handling freshly baked high-temperature workpieces.

Virgin Materials vs. Recycled Materials
Virgin materials have easier-to-control physical properties, making them suitable for environments with high hygiene and cleanliness requirements. Recycled materials are usually more cost-effective and worth evaluating for export or single-use applications. However, material selection shouldn't be based solely on the name; it's essential to request the actual formula and test data from the supplier, especially for applications requiring food contact, antistatic properties, conductivity, or fire resistance.

Molding Method
Injection molding is generally sufficient for warehouses. Only in harsh environments with frequent impacts and drops should a heavier and more robust blow molding process be considered.

V. Selection Based on Usage

Different usage scenarios require different key considerations, summarized in the table below for easy reference:

Usage | Selection Focus

Flat Ground | Static load, bottom flatness

Stacked Goods | Static load, stress distribution, bottom structure

Forklift Handling | Dynamic load, forklift entry direction, insertion port size

Manual Pallet Truck | Wheelbase passage space, bottom structure

Rack Storage | Rack load, deflection, beam distance

Conveyor Belt | Pallet dimensional accuracy, bottom contact surface

Automated Warehousing | Dimensional tolerance, deflection, equipment compatibility

Export Transportation | Dimensions, weight, destination specifications, and cost

VI. Size Selection

Common plastic pallet sizes include 1100×1100 mm, 1200×1000 mm, and 1200×800 mm, but the actual specifications must be determined based on the goods, racks, containers, and handling equipment.

Common Sizes, Common Uses, and Procurement Considerations

1100×1100 mm: Taiwan, Japan, and Asian logistics systems. Confirm cargo bottom and storage equipment.

1200×1000 mm: Industrial logistics, warehousing, and international transportation. Confirm rack and conveyor width.

1200×800 mm: European specifications and export requirements. Confirm destination logistics standards.

1300×1100 mm and above: Large goods, specific production lines. Confirm equipment and container space.

Custom Sizes: Automated equipment, special packaging. May involve mold making, quantity, and delivery time.

When selecting sizes, you can also confirm the following:

• Whether the goods exceed the pallet edge.

• Whether the forklift forks can enter correctly.

• Whether the pallet wheel assembly will hit the bottom structure.

• Whether it conforms to the rack beams and support methods.

• Whether it can pass through conveyors, elevators, and automated storage and retrieval systems.

• Whether it meets the size requirements of the destination logistics system for export.

If you are connecting to an existing automated storage and retrieval system, you should use the equipment specifications as the basis for selection, and not just purchase based on general sizes. VII. Advanced Applications: RFID Smart Pallets for Easier Inventory and Asset Tracking

If you already have an Automated Storage and Retrieval System (AS/RS) or Automated Mobile Transporter (AMR) on-site, or if you frequently experience headaches due to unpredictable pallet locations, consider embedding RFID chips within plastic pallets. This transforms the pallets into data nodes connecting to the WMS (Warehouse Management System).

The chips are embedded in the plastic, making them impact- and water-resistant.

Instead of attaching the chips to the surface, they are directly encapsulated within protective grooves inside the plastic during injection molding. This achieves an IP67 or higher rating for waterproofing and dustproofing. Impacts from forklifts and high-pressure water jets will not affect readability.

What changes will occur after implementation?

• Inbound and outbound operations will use sensor gates: Pallets placed on forklifts will pass through gates equipped with RFID readers. Product name, quantity, and batch number will automatically be entered into the WMS, eliminating the need for manual scanning of each box.

• Significantly reduced inventory time: A single scan by the reader inputs all pallet data for the entire aisle into the system, improving efficiency by at least 80%.

• Clearer asset tracking: Each pallet has a unique identification code, allowing the system to easily track which manufacturer borrowed a pallet and whether it has been returned.

• Navigation for AMRs: In automated warehouses, AMRs or unmanned forklifts read the RFID tags on the bottom of the pallets to confirm that the correct goods have been moved and placed in the correct locations.

Why wooden or metal pallets are not recommended for RFID: Metal blocks radio waves, significantly reducing the reading distance of metal pallets; wood absorbs moisture and can damage the attached RFID chips, and wooden pallets have a short lifespan, making it uneconomical. Engineering plastics like HDPE and PP do not interfere with signals, and plastic pallets are durable, making the cost of chip installation more affordable.

Existing WMS systems typically do not require a complete overhaul; simply creating an API interface allows the RFID reader data to correspond with the existing database. The reading distance depends on the on-site equipment. Industrial-grade UHF RFID can generally achieve a range of 3 to 8 meters, capable of detecting even forklifts driving by.

VIII. Frequently Asked Questions (FAQ)

What size plastic pallet should I choose?

It depends on the bottom surface of the goods, the shelving, the container, the conveyor equipment, and existing logistics standards. Common sizes include 1100×1100 mm and 1200×1000 mm. Special production lines may require other sizes.

Does a static load capacity of 3000 kg mean it can handle 3000 kg?

No. Static load capacity refers to the weight the pallet can bear when laid flat on the ground. During handling, the dynamic load must be considered, and when placed on shelves, the shelf load capacity must be confirmed.

Can plastic pallets be stored in high-bay warehouses?

Some products can, but the shelf load capacity, beam support distance, load distribution, and long-term deflection must be confirmed. Static load capacity alone is insufficient.

Can all plastic pallets be used with manual pallet trolleys?

Not necessarily, especially since the grid-shaped bottom structure can easily jam the wheels. The bottom structure, forklift entry height, and wheel position on the pallet all affect usability; equipment compatibility should be confirmed before purchasing.

Can plastic pallets be used in cold storage?

Some materials and products can, but the actual minimum operating temperature and low-temperature impact resistance must be confirmed. HDPE generally performs better.

Do plastic pallets require fumigation?

Plastic pallets are not wood packaging materials and generally do not require the fumigation treatment used for wooden packaging. However, the destination and customer requirements should still be confirmed before export.

Is switching to plastic pallets really more cost-effective?

The price per piece is usually higher than wooden pallets, but wooden pallets are prone to shedding sawdust, breaking, and protruding nails. Exports also require additional sterilization and fumigation. Plastic pallets can last for an average of five years or more, do not require fumigation, and are washable, resulting in a generally lower long-term total cost.

Can RFID be installed on plastic pallets?

Yes, depending on the product structure, the chip can be encapsulated within an internal protective groove during injection molding for pallet identification, warehouse entry/exit records, and logistics tracking. Waterproof and dustproof ratings can reach IP67 or higher.

How to get a suitable plastic pallet quote?

It is recommended to provide pallet dimensions, cargo weight, handling equipment, stacking method, operating temperature, industry of use, purchase quantity, and any special requirements to obtain an accurate selection and quote.

About Hsintai Plastics Industry: Hsintai Plastics Industry has been involved in the development and manufacturing of industrial packaging, logistics warehousing, and plastic products for over fifty years. They offer plastic pallets in various sizes, structures, and load ratings, ranging from lightweight export pallets to heavy-duty pallets with steel tubing. They can assist with selection based on the needs of automated warehousing, food and pharmaceutical, electronics, chemical, cold chain, and general industrial logistics.

Products are manufactured using HDPE, COPO, PP, or composite materials. Specifications such as dimensions, forklift entry points, static load, and dynamic load are provided for each model. Smart pallet solutions with embedded RFID chips are also supported. If you are unsure about the appropriate specifications, please provide us with the weight of the goods, their dimensions, handling equipment, stacking method, usage environment, and purchase quantity. Shin-Tai Plastics will assist you in evaluating the most suitable product.

View more sizes and specifications on our website: https://zh-tw.shin-tai.com.tw/list/plasticpallet.htm