Everything You Need to Know About Pallets!

read more

Everything You Need to Know About Pallets!

At the heart of pallet racking design is – you guessed it – pallets! In order to design an effective racking system for your North or South Carolina operation, we first need to understand the role of the pallet in that system. The Apex Carolina team has pulled together this comprehensive guide to help you understand the different types of pallets and how that affects the safe operation of your rack. 

PALLETS 101

Pallets come in a variety of different styles, configurations, and even materials – though the most commonly used design is the GMA-style pallet. These pallets are named after the Grocery Manufacturers Association (GMA), which created the following standards in the 1950s.

GMA-Style Pallet Specs: 

  • Wood
  • Stringer-style
  • 40” w x 48” d x 6 1/2” h
  • 7 top & 5 bottom boards – minimum ½” thick
  • Forklift entry from any side
  • Minimum capacity of 2500 lbs
  • Top boards – 5 1/2″ x 40″ on each end & five 3 1/2″ x 40″ boards in the center
  •  Bottom boards – 5 1/2″ x 40″ on each end & three 3 1/2″ x 40″ boards between

When you receive inventory on a 40”w x 48”d x 6 ½’ h wooden pallet, it’s known as GMA-style. Forklifts can easily access these from every side – which gives the operator the ability to drop them either perpendicularly or parallel to the rack opening.

Stringer Pallets

Measuring a GMA-style (stringer) pallet involves three key dimensions:

  • Pallet Width: This dimension, typically 40 inches, pertains to the measurement across the deck boards.
  • Pallet Depth: The depth of the pallet, usually 48 inches, refers to the measurement along the stringers.
  • Pallet Orientation: This term describes the alignment of the stringers concerning the pallet’s position within a lane or bay.

To measure a GMA-style (stringer) pallet accurately, measure across the width of the deck boards, along the length of the stringer, and from the top boards to the bottom of the pallet.

2-WAY VS. 4-WAY PALLET DESIGN

GMA-style pallets can be categorized into two types: 2-way and 4-way pallets. 4-way pallets are equipped with notches in the stringer boards, allowing forklift access from both sides and ends. 2-way pallets lack these notches, which limits their accessibility to only the ends. 

PALLET ORIENTATION

In a standard pallet rack design, pallet orientation is typically 40 inches in width (w) and 48 inches in depth (d). This orientation provides forklift operators with a generous space to safely secure the pallet using their forks while also maximizing the number of pallet positions available.

When designing rack bays for storage deeper than one pallet, an alternative orientation of 48 inches in width (w) and 40 inches in depth (d) can be considered. This configuration offers increased depth in your storage design, benefiting inventories with a low SKU count of high-volume items. However, it’s important to note that opting for this design may lead to a reduction in the total number of lanes available. Additionally, the narrower fork openings can present challenges for forklift operators when securing pallets onto the forks, potentially resulting in beam damage.

OTHER COMMON TYPES OF PALLETS

Block Pallets: Typically, block pallets employ 4 to 12 blocks strategically placed between the top and bottom boards, combined with parallel and perpendicular boards to assemble the pallet securely. An advantage of block pallets is their ability to facilitate 4-way forklift access.

Skid Pallets: Skid pallets are essentially stringer pallets without bottom deck boards.

Square Pallets: Common square pallet sizes include 42” by 42” and 48” by 48”.

Pod Pallets: These are plastic pallets featuring protruding feet (pods) for enhanced stability.

Solid Top Plastic Pallets: Equipped with a smooth top surface to safeguard inventory and storage cases, these pallets also offer convenient 4-way forklift access.

Honeycomb Pallets: Honeycomb pallets are eco-friendly and lightweight corrugated paper pallets designed for one-time use.

Metal Frame Pallets: Available in various designs and sizes. Operators should take note of weld conditions and any other protrusions in the pallet that may affect the safety of operators or inventory. 

Metal Frame Pallet, Plastic Pod Pallet, and Paper Honeycomb Pallet

PALLET QUALITY MATTERS

Poor condition wood pallet

The quality of your pallets plays a crucial role in ensuring the safety of your warehouse, inventory, and the well-being of your workers. Higher-quality pallets significantly reduce the risk of injuries or damage from protruding nails, broken boards, or imbalanced loads.

Wood Pallets

With wooden pallets, you’ll want to opt for Grade B pallets at a minimum. Grade B pallets show some signs of wear and may have some stringer damage that’s been repaired. What’s better is to aim for Grade A pallets, which are the highest quality and do not have damage to the stringers. 

Metal & Plastic Pallets

For metal and plastic pallets, it’s essential to inspect for any broken or protruding welds, as these can result in an uneven surface and create point loads. Plastic pallets, in particular, may feature pod feet instead of a flat bottom surface. Utilizing pallet decking can effectively mitigate challenges associated with these types of pallets, offering a secure and even support surface for both standard and non-standard pallets.

Pod Pallet DeckingBenefits of Pallet Rack Decking

  • Easy Step Beam Installation: Decking effortlessly fits into step beams for quick setup.
  • Pallet Protection: Provides vital support for compromised or damaged pallets, reducing risks and safeguarding your inventory.
  • Enhanced Warehouse Safety: Decking prevents items from falling through, ensuring a secure storage environment.
  • Full Shelf Coverage: Maximizes your storage space with complete surface coverage.
  • Non-Palletized Storage: Accommodates non-palletized items, increasing storage versatility.

By equipping your pallet racking system with decking, you not only enhance safety but also gain the flexibility to maximize your storage capacity, making it a valuable addition to your warehouse infrastructure.

LET’S BUILD YOUR PERFECT WAREHOUSE

Safety is essential to you in your North or South Carolina warehouse – and building a safe warehouse starts with understanding what’s in it! With this in mind, your local Apex team can help you design Selective pallet rack systems and high-density Drive-In, Push-Back, or Pallet Flow solutions that fit your operation. We also offer professional installation, rack maintenance, and repairs. So what are you waiting for? One call does it all.