Custom Pallet Design Examples: Common Problems and How Designs Solve Them
Standard pallets do not work for every application. Explore generic design examples showing how custom dimensions, reinforcement, and board layouts address common shipping problems.
Ace Pallet Service
General pallet education · Published June 2, 2025
When Standard Pallets Fall Short
The 48x40 inch GMA pallet handles most shipping needs in North America, but some loads call for something different. Oversized products, uneven weight, specialized handling equipment, and unusual storage all point toward a custom design.
Custom pallets are practical tools rather than luxury items. A well-designed pallet can help protect the product, fit a trailer or container better, and make handling easier.
The examples below are generic illustrations of design thinking, not records of particular projects. Each one starts with a problem and shows the kinds of design choices that can address it.
Example: Long or Wide Flat Parts
Consider large flat items such as panels or sheet goods. On a standard pallet they may overhang the edges, which leaves corners exposed to forklifts, straps, and neighboring freight.
A common design response is a pallet sized to the part, with a larger footprint so nothing hangs over, and a deck with close board spacing or full perimeter boards so the edges are supported.
Designers also think about stacking. If several panels sit on one pallet, the concentrated weight may call for heavier stringers or extra supports under the load.
Example: Export Loads Sized for Containers
Ocean containers have fixed inside dimensions, and standard North American pallets do not always fill them neatly. Wasted floor space can mean more containers for the same goods.
A design response is to choose a footprint based on the container and the carton size, working out how pallets sit side by side. The 1200x1000 size is one common option for international freight. Block construction gives four-way entry at overseas ports where equipment is unknown.
Because the pallet is crossing a border, the wood should be heat treated to ISPM 15, at 56 °C for 30 minutes, and carry the HT stamp. Check current regulations for the destination.
Example: Heavy Concentrated Machinery
A compressor or similar machine puts a lot of weight on a small footprint, usually through a few feet or a base frame. A standard pallet may not be built to carry that.
A typical design uses thicker hardwood boards, heavier or additional stringers placed directly under the load points, and fixings that let the machine be bolted or strapped down.
If the pallet will sit outside, moisture and decay are also part of the design. Any capacity should be treated as a figure to confirm with the supplier for that particular build.
Getting Started with Custom Pallets
A custom design begins with the application. A supplier will want to know the product dimensions and weight, how the load is distributed, what equipment will handle it, whether it will be racked, and whether it is shipping domestically or abroad.
From there, a supplier can propose dimensions, wood species, board thickness, fastener type, and any special features. For a new design, it is sensible to ask for a sample and test it with your actual load.
Partner suppliers in our network can build to your specification. Send the details through the quote form, and we will match your request with suppliers suited to the job. Pricing depends on design, quantity, freight and market conditions.
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