Pallets are the foundation of warehouse flow—receiving, storage, picking, staging, and shipping all depend on them. But “the right pallet” isn’t one-size-fits-all. The best choice comes down to load weight, hygiene requirements, reuse cycles, shipping lanes (domestic vs international), and total cost over time.
If you’re building or upgrading your operation, start here: Material handling hub and Shop pallets.
If pallets are part of your daily moves, this companion guide helps you match pallets to the right jack: Pallet trucks guide.
Quick comparison: wood vs plastic vs metal pallets
Wood pallets
Best for: general warehousing, cost-sensitive operations, one-way shipping, broad compatibility
Why: widely available, easy to repair, strong value for most standard use cases
Watch-outs: splinters/nails, moisture absorption, harder to sanitize consistently, and international compliance rules for solid wood packaging.
Plastic pallets
Best for: food/pharma, clean environments, export lanes where cleanability matters, reusable loops
Why: consistent dimensions, easier to wash/clean, no splinters
Watch-outs: higher upfront cost, some designs can flex under high point loads, and you still need to confirm suitability for your application.
Metal pallets (steel/aluminum)
Best for: extreme loads, high heat, harsh environments, long-life asset loops
Why: strongest/most durable, great for heavy-duty industrial settings
Watch-outs: higher cost, weight (especially steel), and potential to damage floors or equipment without proper handling.
Wood pallets: when they win
Wood is still the default pallet in many U.S. operations because it’s practical and cost-effective. The U.S. EPA notes that pallets make up a major share of wood packaging and provides data on wood packaging generation and recycling. Source: U.S. EPA
Choose wood if you:
- Ship mixed goods and want the broadest compatibility
- Need easy repair/replacement locally
- Run a high-churn operation (loss is expected)
International shipping note: ISPM 15
If your pallets (or wood packaging) cross borders, ISPM 15 compliance is a must. USDA APHIS explains that wood packaging material entering/transiting the U.S. must be pest-free, treated (heat-treated or fumigated), and properly marked. Source: USDA APHIS CBP also summarizes treatment requirements such as heat treatment. Source: U.S. CBP
Practical takeaway: If export/import is in your plan, treat “ISPM 15-ready” as a spec, not an afterthought.
Plastic pallets: cleanability + consistency (great for regulated lanes)
Plastic pallets are often chosen for sanitary/clean environments where washdown, moisture, and contamination control matter. FDA explains that food contact substances must be authorized for their intended use and provides resources for determining status. Source: U.S. FDA
Choose plastic if you:
- Need easier cleaning and more consistent surfaces
- Operate in food, beverage, pharma, or clean manufacturing
- Want longer life cycles in a closed-loop (you keep the pallets)
Tip: In food environments, confirm material suitability and cleaning practices match your SOPs and product requirements.
Metal pallets: when durability matters more than anything
Metal pallets shine in heavy industry: high load density, abrasive environments, hot processes, and long-term asset tracking.
Choose metal if you:
- Handle very heavy loads repeatedly
- Have extreme heat, sharp edges, or harsh conditions (application dependent)
- Need the longest service life and can justify the upfront cost
How to pick the right pallet in 60 seconds
- How heavy is the typical load? (and peak load)
- Is the load point-heavy? (e.g., machinery feet, coils)
- Is washdown/sanitation required?
- Indoor only or outdoor exposure? (rain, UV, temperature swings)
- Domestic only or international? (ISPM 15 considerations)
- One-way shipping or closed loop? (do pallets return to you?)
- How will you move them? (manual pallet trucks vs powered)
For matching pallets to daily moves, see: Pallet trucks guide.
Safety and storage basics
Pallet choice affects safety, but so does how you store and inspect them. OSHA guidance emphasizes securing stored materials to prevent sliding/falling/collapse. Source: OSHA (PDF)
Simple pallet safety SOP
- Inspect pallets before racking or stacking (cracks, broken boards, bent runners, damaged deck)
- Remove damaged pallets from circulation
- Keep stack heights stable and on level surfaces
- Don’t mix damaged pallets into high racking
Shipping and ordering considerations
If you’re planning bulk purchases or mixed freight (pallets + handling equipment), check shipping terms early: Shipping policy.
Need help selecting pallet types for your lane (export, food-grade, heavy-duty) or a bulk quote? Contact us.
FAQ
Are wood pallets required to be heat-treated?
Only for certain international shipping scenarios. For cross-border movement, ISPM 15 treatment/marking rules often apply. USDA APHIS
Are plastic pallets “food safe”?
Not automatically. FDA explains that food-contact substances must be authorized for their intended use; always confirm the pallet material and use case fit your application. U.S. FDA
Which pallet lasts the longest?
Typically metal (then many plastic designs), but longevity depends on environment, handling method, and repairability.