A pallet that costs a few dollars less can still create an expensive problem if it fails under a load, does not fit a rack, or is rejected for export. Understanding pallet types helps warehouse and shipping teams buy for the actual job instead of defaulting to whatever is available.

The right choice depends on what you ship, how much it weighs, where it is going, how pallets are handled, and whether they will return to your facility. For many businesses, a dependable 48 x 40 wood pallet is the practical starting point. Others need a cleaner plastic option, export-compliant heat-treated lumber, or a custom-built design that protects an unusual product.

The Main Pallet Types Used by Businesses

Most commercial pallet decisions come down to wood, plastic, metal, and custom-built pallets. Each material has a clear place in warehouse operations, but no single option is best for every load or shipping lane.

Wood pallets

Wood pallets remain the most common choice for domestic shipping, distribution, and general warehouse use. They are widely available, easy to repair, and usually the lowest-cost option for standard loads. Standard 48 x 40 pallets are especially common because they work with many trailers, storage systems, forklifts, and shipping programs.

New wood pallets are a good fit when appearance, exact dimensions, or consistent strength matters. They are often used for retail-ready shipments, first-time export shipments, sensitive products, or operations with strict customer requirements.

Refurbished wood pallets offer strong value when the application allows them. A properly repaired pallet can handle routine warehouse movement and outbound shipping at a lower cost than a new pallet. This makes refurbished pallets a sensible option for manufacturers, wholesalers, distributors, and businesses moving high pallet volumes.

The trade-off is variation. Refurbished pallets may show cosmetic wear, and specifications can differ by grade. Buyers should be clear about required deck-board spacing, entry style, load expectations, and whether the pallet will be used in racking.

Plastic pallets

Plastic pallets are durable, consistent in size, and resistant to moisture. They do not have loose nails, splinters, or broken boards, which can make them useful in food handling, pharmaceuticals, clean environments, and closed-loop supply chains.

They also perform well where pallets are exposed to damp conditions or frequent washdowns. Because they are molded to a fixed design, plastic pallets can provide a more consistent fit for automated equipment and conveyor systems.

The main consideration is upfront cost. Plastic pallets usually cost more than wood, and damaged units are not as easily repaired. They make the most financial sense when the pallets are reused repeatedly, recovered after delivery, or needed for a specific cleanliness or moisture-resistance requirement.

Metal pallets

Metal pallets are built for demanding loads, long service life, and specialized industrial environments. Steel or aluminum designs can support heavy machinery, dense materials, drums, and products that would damage standard wood pallets.

These pallets are also common where fire resistance, sanitation, or extended reuse is a priority. Their higher price means they are rarely the first choice for one-way shipping. They are better suited to internal plant movement, returnable programs, and high-value loads where failure is not an acceptable risk.

Custom pallets and crates

A standard pallet works only when the product fits it. Large components, odd-shaped equipment, fragile goods, long materials, and heavy machinery may need a custom pallet, skid, or crate.

Custom designs allow you to control the footprint, lumber thickness, support points, deck layout, and bracing. This reduces shifting during transport and can prevent product damage that costs far more than the packaging itself. For export or high-value freight, a custom crate may provide the protection that stretch wrap and a standard pallet cannot.

Choosing Pallet Types by Load and Handling Method

Start with the load, not the pallet price. Weight is the obvious factor, but load shape and handling matter just as much. A compact 1,500-pound load behaves differently from a tall, uneven shipment with the same total weight.

For standard boxed freight, a quality wood pallet is often sufficient. Make sure the boards and runners are in good condition, especially if forklifts will move the load several times. If products are stored in pallet rack beams, confirm that the pallet is designed for racking. A pallet that is suitable on the floor may flex too much when supported only at its ends.

Forklift access is another practical detail. Two-way pallets can be entered from two sides, while four-way pallets allow forks or pallet jacks to enter from all sides. Four-way entry can improve speed in busy warehouses, tight loading areas, and cross-docking operations.

Block pallets use solid blocks between the top and bottom deck boards, which can offer better support and four-way entry. Stringer pallets use long boards, called stringers, to support the deck. Both are common, but the right design depends on the load, handling equipment, and whether the pallet needs to work in a rack.

Do not overlook pallet condition. Broken boards, protruding nails, missing blocks, and loose components slow down handling and increase safety risks. They can also damage cartons, snag stretch wrap, or cause load instability in transit.

Export Pallets Need Heat Treatment

International shipments using wood packaging often require heat-treated material that meets ISPM-15 requirements. Heat treatment reduces the risk of spreading pests through wood packaging and is identified by an IPPC mark on the pallet or crate.

If your shipment is leaving the country, confirm the destination requirements before loading. A standard domestic wood pallet may not be acceptable for export. The same applies to custom crates, dunnage, and wood bracing used inside a shipment.

Plastic and metal pallets generally avoid wood-treatment requirements, but they may not be the most economical choice for a one-way export shipment. In many cases, a heat-treated wood pallet or crate provides the right balance of cost, strength, and compliance.

New vs. Refurbished Pallets: Make the Practical Call

The decision between new and refurbished pallets is not just about budget. It is about matching the pallet to the risk level of the shipment.

Refurbished pallets are often the better value for local deliveries, routine distribution, warehouse transfers, and shipments where pallets are not returned. They help control packaging costs without compromising everyday performance when supplied to the correct grade.

New pallets are often worth the extra cost when dimensions must be exact, customers have strict receiving standards, the load is heavy or fragile, or the shipment represents your brand at retail. New lumber can also be the better choice when building custom pallet or crate solutions for specialized freight.

A reliable supplier should ask how the pallet will be used before recommending either option. If the answer is simply “the cheapest pallet,” the purchase may solve one cost problem while creating another in handling, damage, or rejected freight.

Plan for Pallet Recovery and Pickup

Pallets accumulate quickly behind warehouses, retail locations, and production facilities. When damaged or surplus pallets are left unmanaged, they take up loading space, create clutter, and can become a safety issue.

Recovery and pickup services give businesses a practical way to clear usable pallets, scrap wood, and excess inventory from their site. For companies that ship frequently, regular pickup can also support a more organized yard and reduce the need to arrange disposal on short notice.

Toronto Pallets can supply standard, refurbished, new, plastic, heat-treated, and custom pallet options while helping businesses manage pallet pickup needs. That combination is useful when supply requirements change from one order to the next.

Ask These Questions Before Ordering

Before placing an order, identify the pallet size you need, the approximate load weight, whether the product will be racked, and how often it will be handled. Also confirm whether the shipment is domestic or international, whether cleanliness requirements apply, and whether pallets will be returned or discarded after delivery.

Those details make it easier to choose between standard wood, refurbished stock, plastic, heat-treated export pallets, or a custom-built solution. They also help prevent last-minute changes at the loading dock.

A good pallet is not necessarily the most expensive one. It is the one that supports the load, works with your equipment, meets the destination requirements, and arrives when your operation needs it. When you are ready to compare options, request a quote with your dimensions, quantity, and intended use so the recommendation is based on the work the pallet actually has to do.