Success Story: Engineering Better Pallets for Heavy, High-Value Freight
How a hands-on approach eliminated product damage and downtime
Industry: Manufacturing & Industrial Components
Customer Overview
A Midwest manufacturer producing large, heavy components relied on custom wooden pallets to move finished products through the plant and to customers nationwide. Repeated pallet failures were slowing operations and putting expensive freight at risk.
Challenge
Their pallets were cracking, bowing, and breaking before loads were even secured, forcing the dock crew to rebuild and repackage freight multiple times per week. The result was lost time, wasted materials, and growing frustration on the floor.
Specific Issues
Under-Built Pallets
Deck boards less than ½ inch thick couldn’t support heavy product weight.
Insufficient Support
Only three stringers were used when four were needed for full load distribution.
Nail Penetration Problems
Nails were driving completely through thin boards, reducing holding strength and causing boards to pop loose.
Pallet Pro’s Solution
Objective
Develop a stronger, purpose-built pallet that could handle oversized, high-value freight without adding unnecessary cost or complexity.
Approach
Our team visited the facility to observe how loads were being staged and handled. After assessing the pallet design, we created on-site samples using thicker deck boards, a four-stringer configuration, and tighter spacing for greater strength and stability. By explaining the design logic directly to the warehouse team, we built confidence in both the process and the product.
Conclusion
The results were immediate. Pallet failures stopped, handling became safer and faster, and the dock crew reported a major improvement in consistency. The manufacturer has since expanded their partnership with Pallet Pro, now requesting new pallet specs as production needs evolve—proof that the right design turns a short-term fix into a long-term solution.
Talk to our team about pallet and crate programs built for your business.
