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Learn more about the production of wooden pallets

2022 | Categories: Logistics

Wooden pallets are a widely used logistic carrier around the world. They are an essential link in the supply chain, storage and transport. According to the latest market research conducted by analysts, the size of the wooden packaging market will increase by over 4% in the period 2019-2023.

Due to the development of e-commerce and the increase in the number of logistics centers, in many countries in Europe, and the United States there is an increasing demand for wooden packaging standardized as EPAL pallets, but also pallets made to order for a specific product.

Mass production of standard wooden pallets

Currently, there are products that immediately convinces with their quality. To guarantee quality every time, automated solutions are great in this matter, due to the saving of materials and repeatability and consistency of production.

The efficiency of CAPE machine production lines allows manufacturers to respond faster to customer requests. With 2-3 employees, the new robot system produces 320-340 pallets per hour, up to 4,500 per day in two shifts. The new CAPE system includes many stations equipped with robots, which undoubtedly increases flexibility and reduces the required number of service employees.

Wooden pallets, i.e. packaging according to a special design

Many manufacturers’ custom-made wooden pallets are delivered with specific options and adaptations for a given task. Custom-made pallets are produced on a semi-automatic line and manually if needed. Each of the pallet elements is made separately, and later a separate line, the individual elements are combined into a complete pallet.

To further streamline production processes, specialized robotic equipment is used. The robot's work accelerates our production and ensures high-quality thanks to 100% repeatability of performed actions. Currently, automated systems can produce over 1,500 pallets every day!

Production of unusual pallets and their impact on business

1. Packaging optimization

Sometimes the product requires special solutions. Sometimes these are extremely heavy products, having large sizes, then special pallets are needed to withstand the weight of such a product. There are many different packaging designs for e.g. home appliances, electronics, pumps, ventilation systems and the construction industry.

Custom-made wooden pallets are delivered according to specific specifications to fully match them to customers products. It also includes matching appropriately durable material, unusual construction, or individual dimensions. Wood gives freedom in the design of even the most complex products.

2. Cost-effectiveness and product safety

Packaging manufactured to product size is very profitable. It gives tangible savings in the supply chain in terms of product protection as well as transport costs. Also, the overproduction of materials is avoided in this way, which undoubtedly favors sustainable development policy around sustainability. Packaging designed for the needs of an individual product facilitates the management of warehouse space without causing an unnecessary waste of space.

3. Other supply chain requirements

Designing pallets on a special order favors the production being optimized at the client's request. Sometimes it may be necessary to design such a packaging so that, for example, the pallet can fit a specific quantity of the product, e.g. 200 pieces — that easily adapts to the customers’ needs.

What does the process of creating and producing a custom pallet look like?

# 1 Step

At the initial stage, we collect all data about the product, packaging method, weight, type of transport, storage method, etc. in a situation where Rotom specialists are to design new packaging. The customer can also come with a specification, then we start production on its basis.

# 2 Step

It concerns the implementation of the preliminary design and its optimization in terms of structure and strength.

# 3 Step

During this time, test patterns shall be involved. We create samples to check how the pallets will react during storage and transport. All this is so that the quality of the packaging does not disappoint our customer.

# 4 Step

Data analysis. We collect information after tests, how the product reacted, whether everything is going according to plan, or maybe you need to make some corrections to the design.

# 5 Step

If it is found after analysis that some changes need to be made, then corrections are made in the project. Although this is extremely rare, manufacturers do not want to skip any stage of production.

# 6 Step

During this time, a trial batch of wooden pallets is produced and finally checked.

# 7 Step

Final Production. When the packaging meets all quality standards, the product orders are introduced to mass production.

At every stage of production of the pallets, full support of specialists from the R&D department as well as sales representatives are assigned.

To sum up, what are the main advantages of wooden pallets?

  • Unusual construction pallets increase the efficiency of the supply chain - which measurably affects savings. Every project made by us is free, so you do not incur additional costs.

  • The designs are not always more expensive than the standards - it turns out that with large production, non-standard pallets bring additional savings instead of costs.

  • The designs do not prevent you from subjecting the pallets to further QC and testing. By using non-standard pallets that you own, you can recover and repair such pallets to reuse them in circulation.

We are an experienced producer of both standard and atypical wooden pallets. We can provide both retail and wholesale quantities. We can produce pallets in virtually every possible dimension! Do you have more questions about wooden pallets? Send an inquiry below or contact us directly.

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