Custom Pallets
When standard sizes do not fit, we build to your exact specifications. Any dimension, any material, any configuration.
Request a Custom Pallet Quote
Share your dimensions, load requirements, and quantity. Our team will design the optimal pallet and provide detailed pricing.
Custom Sizing Capabilities
Standard pallet sizes work for most shipping scenarios, but many industries require pallets that do not conform to the GMA 48x40 format. Oversized industrial equipment, oddly shaped machinery, aerospace components, and specialty agricultural products all demand pallets engineered to their specific dimensions and weight requirements.
At SD Re Pallet, we build custom pallets from 24 inches wide all the way up to 120 inches or larger. If your product needs a 60x60 pallet with reinforced center stringers, or a 36x72 skid with steel runner plates, we design and build it. Our custom pallets are fabricated in our San Diego facility, which means fast turnaround and the ability to iterate on designs without cross-country shipping delays.
We work from your specifications, your engineering drawings, or simply a description of what you need to ship. If you are not sure what dimensions are optimal, our team can evaluate your product dimensions, weight distribution, and shipping method to recommend the ideal pallet design.
Material Options
Hardwood
Oak, Maple, and Birch for maximum load capacity. Hardwood custom pallets are the right choice for heavy industrial equipment, machine tools, and products exceeding 2,500 pounds. Hardwood also resists surface damage better than softwood.
Common for: Machinery, transformers, heavy manufacturing
Softwood
Southern Yellow Pine and Spruce for cost-effective custom builds. Softwood custom pallets offer excellent strength-to-weight ratios and are the standard for most custom applications where the load does not demand hardwood density.
Common for: Consumer goods, electronics, specialty agriculture
Plywood Deck
Plywood decking provides a continuous, smooth surface ideal for small items, irregularly shaped products, and loads that could slip between standard deck boards. Available in various thicknesses for different weight classes.
Common for: Small parts, bagged goods, delicate items
Combination / Hybrid
Mix materials to optimize cost and performance. Hardwood stringers with softwood deck boards, plywood decking on standard runners, or wood frames with steel reinforcement plates for extreme loads.
Common for: Engineered solutions, cost optimization
Heat-Treated Wood
Custom pallets built from ISPM-15 heat-treated lumber for international export. We stamp and certify every heat-treated custom pallet with the proper IPPC mark.
Common for: Export shipments, international freight
Plastic
Custom plastic pallet configurations for hygiene-sensitive applications. Custom plastic pallets require tooling investment, so they are best suited for high-volume, repeating orders.
Common for: Food processing, pharma, clean rooms
Minimum Order Quantities
Our minimum order for custom wood pallets is just 25 units. This low threshold makes custom pallets accessible to small and mid-size businesses, not just large enterprises with massive volumes.
For repeat orders, we keep your pallet specifications on file so reorders are fast and consistent. Many of our customers set up scheduled delivery programs where we manufacture and deliver custom pallets on a weekly or bi-weekly cadence.
Volume discounts kick in at 100 units and become increasingly attractive at 250, 500, and truckload quantities. For ongoing programs of 200 or more pallets per month, we offer dedicated pricing agreements that lock in rates and guarantee availability.
Design Process and Lead Times
Consultation
Share your product dimensions, weight, shipping method, and any special requirements. We discuss material options and configuration. This step takes 1-2 business days.
Design & Quote
We produce a pallet specification document with dimensions, materials, load ratings, and pricing. For complex designs, we may build a prototype for your approval.
Production
Once approved, production typically takes 3 to 7 business days depending on complexity and volume. Rush orders can be accommodated with advance notice.
Delivery
We deliver to your facility on our own fleet throughout the San Diego metro area. See our transportation services for delivery details and service area coverage.
Common Custom Pallet Use Cases
Oversized Industrial Equipment
CNC machines, generators, HVAC units, and other heavy industrial equipment often require pallets that are 60 inches, 72 inches, or larger with reinforced stringer beams and steel corner brackets. We engineer pallets rated for loads up to 10,000 pounds or more.
Aerospace and Defense
Aircraft components, satellite assemblies, and defense hardware demand custom crating and palletization with precise dimensional requirements and often MIL-SPEC packaging compliance. We build pallets to your engineering specifications with documented quality records.
Specialty Agriculture
San Diego County's agricultural sector ships avocados, citrus, flowers, and nursery stock on pallets sized for specific trailer configurations and cooling systems. We build pallets optimized for produce cooling tunnels and reefer trailers.
Non-Standard Racking Systems
If your warehouse uses racking with non-standard beam spacing, standard pallets may overhang or fall through. We build pallets with exact depth and width to match your racking configuration, ensuring safe storage and reliable automated retrieval.
Engineering Specifications and Load Testing
Every custom pallet we build is engineered to meet your specific load requirements. Our design process considers static load (weight at rest), dynamic load (weight during forklift transport), racking load (weight when supported only at the pallet edges on racking beams), and impact resistance during handling and transit.
For loads exceeding 3,000 pounds or for pallets that will be used in racking systems, we perform load distribution analysis to determine optimal stringer spacing, deck board thickness, and fastener patterns. Pallets rated for 5,000 pounds or more use reinforced construction methods including double-thickness stringers, through-bolted connections, and optional steel reinforcement plates at high-stress points.
For critical applications in aerospace, defense, and heavy industrial sectors, we offer formal load testing and certification. Pallets are tested to destruction under controlled conditions and documented with load curves, deflection measurements, and safety factor calculations. This documentation can be included with your shipment for compliance audits and quality records.
Static Load Testing
Pallet is placed on a flat surface with evenly distributed weight incrementally increased until failure. We document the maximum load and apply a safety factor of 3x for the rated capacity. Testing follows ASTM D1185 methodology.
Dynamic Load Testing
Simulates forklift handling with load supported by fork tines at standard spacing (typically 22 to 28 inches). Tests measure deflection under rated load and structural integrity during lifting and lowering cycles.
Racking Load Testing
Pallet is supported only at its edges on simulated racking beams with full load applied in the center span. This is the most demanding test, as the pallet must resist bending without support beneath the load. Critical for any custom pallet used in selective, drive-in, or push-back racking.
Common Custom Pallet Sizes
While we can build any dimension, certain non-standard sizes are requested frequently enough that we maintain dedicated jigs and cutting patterns for faster production.
| Size (L x W) | Industry / Application | Typical Load | Construction | Lead Time |
|---|---|---|---|---|
| 60 x 48" | HVAC equipment, large appliances | 3,000 - 6,000 lbs | 3-stringer hardwood | 5 - 7 days |
| 72 x 48" | Machinery, generators | 5,000 - 10,000 lbs | 4-stringer reinforced | 5 - 7 days |
| 96 x 48" | Long goods, steel beams, pipe | 4,000 - 8,000 lbs | 4-stringer with center support | 7 - 10 days |
| 120 x 48" | Oversized industrial, aircraft parts | 6,000 - 15,000 lbs | Block or 5-stringer with steel | 10 - 14 days |
| 36 x 36" | Small footprint, retail display | 1,000 - 2,500 lbs | 2-stringer softwood | 3 - 5 days |
| 48 x 36" | Narrow racking, specialty agriculture | 1,500 - 3,000 lbs | 3-stringer softwood | 3 - 5 days |
| 60 x 60" | Square loads, transformers | 4,000 - 8,000 lbs | 4-stringer hardwood | 5 - 7 days |
| Custom skids | Heavy equipment, export crating | Up to 20,000+ lbs | Engineered per spec | 7 - 14 days |
Material Options Matrix
Selecting the right material combination for your custom pallet depends on load weight, environmental exposure, budget, and regulatory requirements. Use this matrix to identify the optimal combination.
| Material | Load Rating | Moisture Resistance | Cost Level | Export Ready |
|---|---|---|---|---|
| Softwood (SYP) | Up to 3,500 lbs | Low | $ | With HT stamp |
| Hardwood (Oak) | Up to 8,000 lbs | Low-Medium | $$ | With HT stamp |
| Plywood deck on wood stringers | Up to 4,000 lbs | Medium | $$ | With HT stamp |
| Wood with steel reinforcement | Up to 15,000+ lbs | Medium | $$$ | With HT stamp |
| Plastic (HDPE injection) | Up to 30,000 lbs | Waterproof | $$$$ | Exempt (no treatment) |
| Combo (hardwood + plywood + steel) | Up to 20,000 lbs | Medium-High | $$$$ | With HT stamp |
Minimum Orders and Lead Times by Complexity
Lead times and minimum order quantities depend on the complexity of the design, materials required, and whether we have existing jigs for your dimensions. Here is a detailed breakdown.
| Complexity Level | Description | Minimum Order | Standard Lead Time | Rush Lead Time |
|---|---|---|---|---|
| Simple | Non-standard size, standard construction (2-3 stringers, flat deck) | 25 units | 3 - 5 business days | 1 - 2 business days |
| Moderate | Non-standard with 4+ stringers, plywood deck, or special features | 25 units | 5 - 7 business days | 3 - 4 business days |
| Complex | Oversized (60"+), steel reinforcement, multi-material, wing or flush design | 50 units | 7 - 10 business days | 5 - 7 business days |
| Engineered | Load-tested, certified, MIL-SPEC or custom crate with integrated pallet | 10 units | 10 - 14 business days | 7 - 10 business days |
Engineered pallets have a lower minimum order because each unit requires more design and fabrication time. Volume discounts begin at 100 units for simple and moderate complexity, and at 50 units for complex and engineered builds.
Design Consultation Process: What to Expect
Whether you come to us with a detailed engineering drawing or just a rough description of what you need to ship, our design consultation process ensures you end up with a pallet that is optimized for your product, your handling equipment, and your budget.
Information We Need From You
- Product dimensions (length x width x height) and weight
- Number of units per pallet (if multiple items per load)
- Weight distribution (uniform or concentrated point loads)
- Racking type and beam spacing (if stored on racks)
- Shipping method (LTL, FTL, ocean container, air freight)
- Domestic or international destination
- Order volume and frequency
What We Deliver
- Pallet specification sheet with dimensions and construction details
- Rated load capacities (static, dynamic, and racking)
- Material bill and wood species recommendation
- Per-unit pricing with volume discount tiers
- Production timeline and delivery schedule
- Prototype sample for approval (complex builds, available upon request)
- Load test documentation (engineered builds, available upon request)
The consultation process is free with no obligation to order. We believe in earning your business by demonstrating expertise and delivering a solution that genuinely fits your needs. Start your consultation today or call us directly to discuss your project.
Ready to Build Your Custom Pallet?
Whether you have detailed blueprints or just a rough idea, our team will work with you to create the perfect pallet. Low minimums, fast turnaround, competitive pricing.