Alternatives to Wooden Pallets

Wooden pallets are suitable for many industrial applications, but sometimes you need something stronger, splinter-free and easy to clean. Whether you’re looking for the most sanitary type of pallet or for the best pallet for shipping your particular product, you can choose from several alternative options, including plastic, metal, wire mesh and corrugated pallets.

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Possible Disadvantages of Wooden Pallets

Many business owners and warehouse operators find wooden pallets to be both inconvenient and ineffective, especially compared to durable alternatives like plastic and aluminum. If you’re unsure about making the switch, here are some possible disadvantages associated with wooden pallets:

There are longer-lasting alternatives: Although wooden pallets can be reused multiple times — especially if they are handled and stored properly — alternative pallets last far longer. After prolonged use, the wooden planks will begin to splinter and loosen, eventually breaking or warping. If pallets are not stored correctly, they can also attract insects. Plastic, metal and wire versions, however, are crafted with longer-lasting materials.
They can be a safety hazard: Because they are easily damaged, wooden pallets can be a safety hazard to all who handle them. They can splinter, crack or harbor harmful bacteria.
They are easily stained: Wood is very porous, which is why wooden pallets hold on to stains, even after they are cleaned. This issue is also why many countries no longer allow wooden pallets around sensitive materials, like food.

Clean Alternatives to Wooden Pallets

Several industries, including food service and the medical sector, have rigorous hygiene standards for all products and product handling materials. The FDA Food Safety Modernization Act (FSMA) issued a final rule on the Sanitary Transportation of Human and Animal Food. This guideline requires that all personnel who transport food products must ensure shipping equipment does not have any residue that can cross-contaminate with new products.

This regulation means pallets must consist of an easy-to-clean material that can be sanitized and disinfected regularly. Wooden pallets absorb spills and can harbor dangerous bacteria that can contaminate other products or harm the workers handling the pallets.

If your warehouse or business needs easy-to-clean pallets without sacrificing performance and durability, here are some alternative options to consider:

1. Plastic Pallets

Plastic pallets are designed using strong, non-porous materials like high-density polyethylene (HDPE), low-density polyethylene (LDPE), polypropylene (PP), copolymer blends and other recycled plastics. Because these pallets are long-lasting, versatile and hygienic, many consider them as the best alternative to wooden pallets.

Some benefits of plastic pallets include:

Durability: Plastic pallets are strong and adapt easily to fluctuating temperatures. Unlike wooden versions, you don’t have to worry about loose boards, nor do you need to stress over your equipment corroding and breaking down over time. They are ideal for international exporting. Many plastic pallets are also recyclable.
Hygiene: Plastic pallets are a top sanitary alternative to wooden pallets because they can be easily washed down with high-temperature water and don’t retain moisture. Afterward, plastic pallets dry quickly, which means more efficient packaging and shipping. Additionally, many plastic pallets consist of a single piece, eliminating nooks and crannies where debris and bacteria can often hide. Finally, because they are easy to wash and non-porous, plastic pallets are odor resistant.
Safety: With plastic pallets, you don’t have to worry about painful splinters or loose nails. They also resist toxic chemicals that can cross-contaminate other products and jeopardize the safety of anyone handling the equipment.
Customizability: Plastic pallets are highly versatile and available in several different varieties, including stackable, nesting and solid top designs. For even more convenience, Cherry’s offers customizable plastic pallets, so you know you’re getting the exact size and type suitable for your business.

2. Metal Pallets

If you value pallets that don’t splinter — all while offering uncompromising strength — metal is the way to go. Metal pallets are strong and easy to reuse, and, unlike wood and plastic varieties, they are fire-safe. Because they are durable, metal pallets are a long-term investment you can reuse many times over in several different capacities. The two most common types are steel and aluminum:

Steel pallets: Steel pallets have a large load capacity compared to other types of pallets, making them ideal for heavy shipments. They are easy to clean and sanitize and, like plastic pallets, can withstand high temperatures. They can be painted or powder-coated for easy warehouse organization or industry branding.
Aluminum pallets: Aluminum is more lightweight than steel, yet durable. Aluminum pallets are washable, rust-resistant and bacteria-resistant. One of the best benefits of aluminum pallets is that, when you finish using them, they are fully recyclable — and often for profit. Cherry’s offers customizable aluminum pallets, so you can choose your exact dimensions and design.

As you consider this wooden pallet alternative, keep in mind metal pallets are heavier than other materials and may require special handling equipment.

3. Wire Mesh Pallets

Wire mesh pallets are a good choice for warehouses or businesses that need something sturdy and long-lasting without too much additional weight or maintenance required.

Some reasons to consider wire mesh for your next pallet include:

Higher load-bearing capacity: In addition to an after-weld finish that promotes stable load-bearing, our standard wire mesh pallets have a 4,000-pound stack capacity. These pallets have reinforced channels and can often handle larger loads than aluminum and wood versions. This factor is partly because wire mesh pallets have interwoven wire, which distributes load weight more efficiently than other types that may suffer from sagging or breaking panels after prolonged use. Durable pallets translate to a long lifespan and less money you have to spend replacing them. Despite their durability, wire mesh is also lightweight and easily configurable during shipping and when stored.
Easier handling: Wire mesh pallets are easy for workers to handle because they are easily stackable and accessible by a forklift on all four sides. Simple handling can save time that can be allotted elsewhere.
More available options: In addition to stackable versions, you can purchase nesting wire pallets, as well as customizable options that meet specific dimensions. These options help you maximize every square footage of space in your facility. When you finish using wire mesh pallets, you can also recycle them.
Simpler maintenance: Wire mesh is pre-treated with a special anti-rust coating that makes it easy to care for. You can clean and disinfect wire mesh pallets efficiently, and, thanks to the design, they dry very quickly. Unlike wooden pallets wire mesh does not rot, warp, or splinter when wet. While plastic pallets offer similar benefits, wire mesh is often more affordable for those operating under a strict budget.

4. Corrugated Pallets

Corrugated pallets consist of corrugated fiberboard, laminated paperboard or cardboard and are held together with strong paper cores — or even staples and glue. Many contain post-recycled materials and can be easily recycled after use, making them an environmentally sound option. They are extremely lightweight, and many can fold or collapse when not in use. Because they are so light, they are often more economical to ship than wooden pallets. Despite their design, they can withstand heavy loads and do not splinter.

Untreated corrugated pallets are susceptible to moisture damage, but you can opt for ones with more moisture resistance. Similarly to wooden pallets, many corrugated pallets can absorb substances and are not usually safe around hazardous liquids or chemicals. This issue is especially true since they cannot be thoroughly cleaned like plastic and metal pallets.

The most significant drawback of corrugated pallets is that they cannot be used more than once or twice before they need to be recycled and replaced. While the initial cost of investment is lower than many alternatives, the cost of replacement is important to consider.

How to Keep Pallets Clean

When it comes to cleaning and maintaining wooden pallet alternatives, you have several options, depending on the type of clean you need. Sometimes, the job calls for a quick wipe down in the warehouse before storage. Other times, pallets require heat sterilization or need cleaning from a professional pallet washing system.

Manual Cleaning

Manual pallet cleaning is a good way to keep pallets clean in between uses or before and after prolonged storage, especially if you only need to wash a few at a time. Some manual cleaning methods include:

Wipe down: Warehouse workers can use a cleaning cloth and a material-safe cleaning solution to wipe pallets down when they are dusty or have experienced non-toxic spills. Just be sure to use a cleaning solution safe for the pallet type being cleaned, as some metal cleaners might not be suitable for plastic pallets. Although wiping pallets down is a quick and easy way to clean up messes, it is not ideal for deep cleaning or disinfecting of any kind.
Power-wash: For tougher messes that do not require sterilization, pressure washing might be a viable option. Power washers exert a steady, high-pressure flow of water that can cut through thick layers of grime. For extremely dirty pallets, it might be a good idea to power wash away the first few layers of dirt before using an automatic pallet washer to finish the job. Although pressure washers are very good at eliminating filth and debris from pallets, this method is not an alternative to sterilization.
Heat sterilization: Heat sterilization requires more care than other manual cleaning methods and is usually required for FDA pallets or those transporting food or medical supplies. During heat sterilization, the temperature must reach and sustain a minimum of 165 degrees Fahrenheit. Heat sterilization should always be conducted in a separate, sterile room where pallets can be securely packaged and stored away from contaminants afterward.

Pallet Washers and Dryers

If you are cleaning many pallets at once or require a deep, thorough wash, industrial pallet washers and dryers may be a worthwhile investment for your workplace. Cherry’s offers both automatic and manual industrial pallet washers that are made from stainless steel and equipped with high-impact pressure nozzles.

Industrial washers can remove and sanitize challenging debris, like oil, grease, dirt, mud and powder. Additional benefits of an industrial pallet washer from Cherry’s include:

Efficiency: The faster you can clean and sanitize your pallets, the sooner you can get back to business. Our industrial washers can wash and dry up to 200 pallets per hour, saving you time and money.
Consistent quality: With an automatic washer, enjoy a thorough, consistent wash every time.
Control panel access: Controls are fully operational, and you can choose your ideal wash time with a panel.
No cross-contamination: Pallets are washed in independent stages to eliminate cross-contamination risk.
Cleanliness: No spot is left unwashed thanks to multiple, complete coverage spray nozzles.
Hands-off washing: Strong rollers move pallets through washing cycles, including exit brushing.

Our automatic washer systems come with a built-in dryer for ultimate ease of use. Industrial pallet dryers are:

Effective: Built-in vertical air knives blow 95% of pallet moisture away, and heat dries the rest. Because our pallet dryers can reach temperatures up to 200 degrees Fahrenheit, you can expect your equipment to dry quickly and thoroughly.
Energy-efficient: By recirculating up to 90% of dried air and utilizing heat-retaining steel, Cherry’s pallet dryers also provide energy efficiency.

Cherry’s Material Handling Has Wooden Pallet Alternatives

Wooden pallets are porous, impossible to sterilize and depending on their condition and the circumstances can put workers and products at risk. Alternative pallets, like steel, aluminum and wire mesh, are more durable, hygienic and suitable for international transport. If you’re ready to make the switch, Cherry’s Material Handling has high-quality wooden pallet alternatives.

In addition to industrial plastic, metal and wire mesh pallets, we also offer pallet storage and moving accessories, such as:

Industrial pallet racking systems, including step beams, tear drop frames, uprights and support bars.
Manual, semi-electric and full power industrial pallet stackers.
Manual, electric, specialty, all-terrain and custom pallet trucks and jacks.

Cherry’s Material Handling has all the industrial equipment you need in a single, convenient online location. Browse our inventory or contact us to learn more about what our custom material handling products and warehouse solutions can offer your workplace.