Custom Pallets
When standard sizes do not fit, partner suppliers in our network can build pallets to your specifications, in a wide range of dimensions, materials, and configurations.
Request a Custom Pallet Quote
Share your dimensions, load requirements, and quantity. We will pass your request to a partner supplier in our network, who will follow up with design options and pricing.
Custom Sizing Capabilities
Standard pallet sizes work for most shipping scenarios, but many industries require pallets that do not conform to the GMA 48x40 format. Oversized industrial equipment, oddly shaped machinery, aerospace components, and specialty agricultural products all demand pallets engineered to their specific dimensions and weight requirements.
Through SD Re Pallet, you can request custom pallets from partner suppliers in our San Diego County network, from small 24-inch footprints up to 120 inches or larger. If your product needs a 60x60 pallet with reinforced center stringers, or a 36x72 skid with steel runner plates, describe it in your request. Working with a local supplier can make it easier to iterate on designs without cross-country shipping delays.
Suppliers can typically work from your specifications, your engineering drawings, or simply a description of what you need to ship. If you are not sure what dimensions are best, include your product dimensions, weight distribution, and shipping method so the supplier can recommend a design.
Material Options
Hardwood
Oak, Maple, and Birch for maximum load capacity. Hardwood custom pallets are the right choice for heavy industrial equipment, machine tools, and products exceeding 2,500 pounds. Hardwood also resists surface damage better than softwood.
Common for: Machinery, transformers, heavy manufacturing
Softwood
Southern Yellow Pine and Spruce for cost-effective custom builds. Softwood custom pallets offer excellent strength-to-weight ratios and are the standard for most custom applications where the load does not demand hardwood density.
Common for: Consumer goods, electronics, specialty agriculture
Plywood Deck
Plywood decking provides a continuous, smooth surface ideal for small items, irregularly shaped products, and loads that could slip between standard deck boards. Available in various thicknesses for different weight classes.
Common for: Small parts, bagged goods, delicate items
Combination / Hybrid
Mix materials to optimize cost and performance. Hardwood stringers with softwood deck boards, plywood decking on standard runners, or wood frames with steel reinforcement plates for extreme loads.
Common for: Engineered solutions, cost optimization
Heat-Treated Wood
Custom pallets built from ISPM-15 heat-treated lumber for international export. Partner suppliers can supply ISPM-15 stamped pallets carrying the IPPC mark on request.
Common for: Export shipments, international freight
Plastic
Custom plastic pallet configurations for hygiene-sensitive applications. Custom plastic pallets require tooling investment, so they are best suited for high-volume, repeating orders.
Common for: Food processing, pharma
Minimum Order Quantities
Minimum orders for custom wood pallets vary by supplier and design, but many suppliers will build relatively small runs, which makes custom pallets accessible to small and mid-size businesses, not just large enterprises.
For repeat orders, ask the supplier to keep your pallet specifications on file so reorders are faster and consistent. Some suppliers can also build and deliver repeat orders on a regular schedule.
Per-unit pricing usually improves at larger quantities, such as 100, 250, 500, and truckload orders. For ongoing programs, some suppliers offer pricing agreements for recurring volume.
Design Process and Lead Times
Consultation
Share your product dimensions, weight, shipping method, and any special requirements. We pass your request to a partner supplier, who discusses material options and configuration with you.
Design & Quote
The supplier prepares a specification with dimensions, materials, load ratings, and pricing. For complex designs, ask about a prototype for your approval.
Production
Once approved, the supplier schedules production. Timing depends on complexity, volume, and the supplier, and is confirmed in the quote. Ask about rush options if your timeline is tight.
Delivery
Delivery within San Diego County is available through partner suppliers. See transportation services for delivery details and service area coverage.
Common Custom Pallet Use Cases
Oversized Industrial Equipment
CNC machines, generators, HVAC units, and other heavy industrial equipment often require pallets that are 60 inches, 72 inches, or larger with reinforced stringer beams and steel corner brackets. Heavy-duty custom pallets can be built for loads of 10,000 pounds or more.
Aerospace and Defense
Aircraft components, satellite assemblies, and defense hardware demand custom crating and palletization with precise dimensional requirements. Request pallets built to your engineering specifications and ask the supplier about documentation.
Specialty Agriculture
San Diego County's agricultural sector ships avocados, citrus, flowers, and nursery stock on pallets sized for specific trailer configurations and cooling systems. Custom pallets can be sized for produce cooling tunnels and reefer trailers.
Non-Standard Racking Systems
If your warehouse uses racking with non-standard beam spacing, standard pallets may overhang or fall through. Custom pallets can be built with the depth and width to match your racking configuration, supporting safe storage and reliable automated retrieval.
Engineering Specifications and Load Testing
A well-designed custom pallet is built around your specific load requirements. Good design considers static load (weight at rest), dynamic load (weight during forklift transport), racking load (weight when supported only at the pallet edges on racking beams), and impact resistance during handling and transit.
For loads exceeding 3,000 pounds or for pallets that will be used in racking systems, load distribution analysis helps determine stringer spacing, deck board thickness, and fastener patterns. Pallets rated for 5,000 pounds or more typically use reinforced construction methods such as double-thickness stringers, through-bolted connections, and steel reinforcement plates at high-stress points.
For critical applications in aerospace, defense, and heavy industrial sectors, formal load testing may be required. In this kind of testing, sample pallets are loaded to failure under controlled conditions and documented with load curves, deflection measurements, and safety factor calculations. If you need test documentation, say so in your request so the supplier can confirm whether they can provide it.
Static Load Testing
Pallet is placed on a flat surface with evenly distributed weight incrementally increased until failure. The maximum load is recorded and a safety factor is applied to set the rated capacity. ASTM D1185 is a common reference method.
Dynamic Load Testing
Simulates forklift handling with load supported by fork tines at standard spacing (typically 22 to 28 inches). Tests measure deflection under rated load and structural integrity during lifting and lowering cycles.
Racking Load Testing
Pallet is supported only at its edges on simulated racking beams with full load applied in the center span. This is the most demanding test, as the pallet must resist bending without support beneath the load. Critical for any custom pallet used in selective, drive-in, or push-back racking.
Common Custom Pallet Sizes
Custom pallets can be built in a wide range of dimensions, but certain non-standard sizes come up often. Loads below are typical ranges and vary by supplier and design.
| Size (L x W) | Industry / Application | Typical Load | Construction |
|---|---|---|---|
| 60 x 48" | HVAC equipment, large appliances | 3,000 - 6,000 lbs | 3-stringer hardwood |
| 72 x 48" | Machinery, generators | 5,000 - 10,000 lbs | 4-stringer reinforced |
| 96 x 48" | Long goods, steel beams, pipe | 4,000 - 8,000 lbs | 4-stringer with center support |
| 120 x 48" | Oversized industrial, aircraft parts | 6,000 - 15,000 lbs | Block or 5-stringer with steel |
| 36 x 36" | Small footprint, retail display | 1,000 - 2,500 lbs | 2-stringer softwood |
| 48 x 36" | Narrow racking, specialty agriculture | 1,500 - 3,000 lbs | 3-stringer softwood |
| 60 x 60" | Square loads, transformers | 4,000 - 8,000 lbs | 4-stringer hardwood |
| Custom skids | Heavy equipment, export crating | Up to 20,000+ lbs | Engineered per spec |
Material Options Matrix
Selecting the right material combination for your custom pallet depends on load weight, environmental exposure, budget, and regulatory requirements. Use this matrix to identify the optimal combination.
| Material | Load Rating | Moisture Resistance | Cost Level | Export Ready |
|---|---|---|---|---|
| Softwood (SYP) | Up to 3,500 lbs | Low | Low | With HT stamp |
| Hardwood (Oak) | Up to 8,000 lbs | Low-Medium | Medium | With HT stamp |
| Plywood deck on wood stringers | Up to 4,000 lbs | Medium | Medium | With HT stamp |
| Wood with steel reinforcement | Up to 15,000+ lbs | Medium | High | With HT stamp |
| Plastic (HDPE injection) | Up to 30,000 lbs | Waterproof | Highest | Exempt (no treatment) |
| Combo (hardwood + plywood + steel) | Up to 20,000 lbs | Medium-High | Highest | With HT stamp |
Minimum Orders, Lead Times, and Pricing
Minimum order quantities and lead times depend on the complexity of the design, the materials required, and the supplier. A non-standard size with standard construction is usually quicker to build than an oversized, steel-reinforced, or load-tested design. Pricing is by quote from partner suppliers and depends on grade, size, quantity and timing; the partner supplier that quotes your order will confirm minimums and timing.
Design Consultation Process: What to Expect
Whether you have a detailed engineering drawing or just a rough description of what you need to ship, the more information you include in your request, the better a supplier can match a pallet to your product, your handling equipment, and your budget.
Information We Need From You
- Product dimensions (length x width x height) and weight
- Number of units per pallet (if multiple items per load)
- Weight distribution (uniform or concentrated point loads)
- Racking type and beam spacing (if stored on racks)
- Shipping method (LTL, FTL, ocean container, air freight)
- Domestic or international destination
- Order volume and frequency
What to Ask the Supplier For
- Pallet specification sheet with dimensions and construction details
- Rated load capacities (static, dynamic, and racking)
- Material bill and wood species recommendation
- Per-unit pricing at the quantities you need
- Production timeline and delivery schedule
- Prototype sample for approval (complex builds, available upon request)
- Load test documentation (engineered builds, available upon request)
Requesting a quote is free with no obligation to order. Request a quote with your project details and we will pass it to a partner supplier in our network.
Ready to Build Your Custom Pallet?
Whether you have detailed blueprints or just a rough idea, tell us what you need and we will connect you with a partner supplier in our San Diego County network.