Built to Your Exact Spec
Non-standard dimensions, notched stringers, painted decks, branded prints — if you can describe it, we can build it.
Any Dimensions
We cut and build to any length, width, and height. Minimum order may apply for very small batches.
Species & Grade Selection
Southern Yellow Pine, Oak, Mixed Hardwood. Specify your wood species for maximum load capacity.
Entry Options
2-way, 4-way full, 4-way partial. Notched stringers for pallet jack clearance.
Surface Treatments
Heat treatment (HT), kiln-dried (KD), pressure-treated, painted, stained, or anti-slip coated.
Block or Stringer
Block pallets for all-way entry; stringer pallets for maximum deck coverage. We build both.
Branded Pallets
Your logo or text burned or painted onto the deck. Great for retail display and brand visibility.
Minimum Order Quantities
Non-standard sizes using standard lumber
Special materials, treatments, or branding
From Concept to Finished Pallet
Our custom pallet design process is collaborative and engineering-driven. We don't just cut wood to your dimensions — we design a pallet that optimizes load capacity, material cost, and operational efficiency for your exact use case.
Consultation & Requirements
We start with a detailed conversation about your application: what product sits on the pallet, how heavy it is, how it's handled (forklift, pallet jack, crane), where it ships, and how many trips it needs to survive. We also discuss racking requirements, container fit, and compliance needs.
Engineering & PDS Analysis
Using the NWPCA Pallet Design System (PDS), our team models your pallet configuration with specific lumber species, board dimensions, and fastener patterns. PDS calculates predicted load capacity, deflection under load, and estimated durability. We optimize the design to minimize material cost while exceeding your load requirements.
Prototype & Approval
For orders over 500 units, we build a physical prototype for your approval before full production. You can inspect the prototype, test-fit your product, and verify compatibility with your handling equipment. Prototypes are typically ready within 3-5 business days.
Production & Delivery
Once approved, production begins on a dedicated line. Standard custom orders complete in 7-10 business days. Rush orders (with 50%+ surcharge) can be completed in 3-5 days. Pallets are shrink-wrapped per stack, loaded on flatbed trucks, and delivered to your facility on your schedule.
Hardwood, Softwood, or Composite — Your Choice
Material selection is the single biggest factor in pallet performance, weight, and cost. We stock three material categories and can combine them for hybrid builds that optimize specific performance characteristics.
Hardwood Custom Pallets
Oak, maple, birch, ash, and poplar — each species offers different strength, weight, and cost characteristics. Hardwood pallets are the preferred choice when maximum load capacity is the priority. Our hardwood inventory includes:
- Red Oak
Highest strength. 14,300 PSI MOR. Heavy (47 lbs/ft3). Best for extreme loads — automotive parts, steel coils, machinery.
- White Oak
Rot-resistant. Excellent for outdoor or marine exposure applications. Slightly more expensive than red oak.
- Hard Maple
Very hard, wear-resistant surface. Great for pallets used in automated conveyor systems where surface durability matters.
- Yellow Birch
Good strength-to-weight ratio. Clean appearance for retail-facing applications. Moderate cost.
- Poplar
Lightest hardwood option. Moderate strength. Best value for applications that need hardwood classification without premium weight.
Softwood Custom Pallets
Southern Yellow Pine, Douglas Fir, Spruce, and Pine-Spruce-Fir (SPF) blends. Softwood pallets are lighter, less expensive, and easier to manufacture. They handle standard loads efficiently and are the default material for export pallets due to faster heat-treatment times.
- Southern Yellow Pine
Industry standard softwood. Excellent nail holding. 12,800 PSI MOR. Most widely available and consistently graded.
- Douglas Fir
Strong for a softwood — 12,400 PSI MOR. Stiff and straight-grained. Common in western US manufacturing.
- Spruce-Pine-Fir (SPF)
Imported from Canada. Consistent grade. Lighter than SYP. Good for standard domestic applications at competitive pricing.
- White Pine
Soft, lightweight, easy to cut. Lowest cost softwood. Suitable for light-duty and one-way applications only.
Composite & Specialty Materials
For specialized environments where traditional wood isn't optimal, we offer composite and engineered material options. These include plywood, OSB, and presswood components that can be combined with solid wood for hybrid designs.
- Plywood Deck
Solid plywood decking eliminates board gaps for small-item support. 3/4-inch CDX plywood provides smooth, continuous surface. Reduces product damage for irregularly shaped loads.
- OSB (Oriented Strand Board)
Engineered wood panel for deck surface. More economical than plywood. Good for light-to-medium loads. Smooth surface prevents product snagging.
- Presswood / Molded
Compressed wood fiber pallets. Lightweight (15-20 lbs). Exempt from ISPM 15 heat treatment. Nestable design saves storage space. Ideal for one-way air freight.
- HDPE Plastic
High-density polyethylene pallets for cleanroom, pharmaceutical, and food-grade environments. Washable, chemical-resistant, FDA compliant. 30+ year lifespan.
- Metal Reinforced
Steel-reinforced wood pallets for extreme loads exceeding 8,000 lbs. Steel channel runners with hardwood decking. Custom fabrication only.
Custom Branding & Identification
Branded pallets serve double duty — they carry your product and promote your brand. Whether you need simple identification markings for logistics tracking or full-color branded displays for retail environments, we offer multiple branding methods.
Heat Branding (Burn Stamping)
A heated metal die presses your logo, text, or tracking codes directly into the wood surface. The result is a permanent, professional mark that never fades, peels, or washes off. Heat branding is the most durable option and the industry standard for pallet ownership identification.
Maximum brand area: 8x4 inches. Setup cost: $150-$300 for custom die. Per-pallet cost: $0.50-$1.00. Lead time for custom die: 5-7 business days.
Stencil Painting
Your logo, company name, or handling instructions are stencil-painted onto the pallet deck or stringer using weather-resistant industrial paint. Available in any standard color. Paint brands are visible from distance and are the preferred method for color-coded warehouse systems.
Maximum area: 12x6 inches per stencil. Colors: any PMS color available. Per-pallet cost: $0.75-$1.50. Stencil setup: $75-$150.
Ink Jet Printing
High-resolution ink jet printing for barcodes, QR codes, serial numbers, and variable data. Each pallet can receive a unique identifier for asset tracking and inventory management. Compatible with most warehouse management systems (WMS).
Resolution: up to 300 DPI. Maximum print area: 6x3 inches. Variable data capable. Per-pallet cost: $0.25-$0.75. No setup fee for standard formats.
Full-Color Shrink Sleeve
For ultimate brand impact, we wrap pallet deck boards with full-color printed shrink-sleeve graphics. Used for retail point-of-purchase displays, trade show pallets, and brand activation events where the pallet is part of the visual presentation.
Full CMYK color process. Minimum order: 100 pallets. Per-pallet cost: $3.00-$8.00. Artwork setup: $250-$500. Weather resistant for indoor use.
Custom Engineering Specifications
When you order a custom pallet, you have full control over every engineering parameter. Here are the specifications you can define — and the ranges we support.
24x24 in minimum to 72x120 in maximum. Any increment in 1/2-inch steps.
3.5 in to 5.5 in. Standard is 3.5 in for economy, 5.5 in for heavy-duty.
5/16 in (economy) to 3/4 in (heavy-duty). Standard is 7/16 in.
1.5x3.5 in (standard) to 2x6 in (heavy-duty). Notched or un-notched.
3.5x3.5x3.5 in (standard) to 4x6x4 in (heavy-duty). Hardwood or softwood.
5-board (economy) to 11-board (full-coverage). Top and bottom decks can differ.
Ring-shank nails (standard), screw-shank nails, screws, or bolts for extreme applications.
2-way, 4-way partial (notched stringer), 4-way full (block construction).
Heat-treated (HT), kiln-dried (KD), pressure-treated (CCA/ACQ), or untreated.
Anti-slip coating, paint (any color), wood stain, polyurethane, or epoxy sealant.
Production Lead Times
Lead times depend on the complexity of your custom specification, material availability, and order volume. Here are our standard timelines.
Standard Custom Sizes
Non-standard dimensions using standard lumber species in stock. No special treatments or branding.
Custom with Heat Treatment
Custom sizes requiring ISPM 15 heat treatment. Additional 2-3 days for HT kiln scheduling.
Branded / Painted Custom
Custom pallets with branding, stenciling, or special paint finishes. Includes die/stencil fabrication time.
Full Custom Build
Special materials, non-standard lumber species, composite components, or engineered specifications.
Rush Custom Orders
Available for standard custom sizes with a 50% rush surcharge. Subject to production capacity.
Repeat Orders Ship Faster
Once we have your custom specifications on file, repeat orders skip the design phase and enter production within 24 hours. We maintain your specifications, die templates, and material preferences in our system — just call and say "same as last time" and we handle the rest.
Custom Projects We've Built
Every custom pallet is designed for a specific purpose. Here are examples of custom projects we've completed for San Diego area businesses — to give you an idea of what's possible.
Aerospace Component Pallets
Custom 60x48 inch pallets with plywood top deck (zero gaps), foam-lined cradle supports, and anti-static coating for sensitive avionics components. 9-block construction rated to 4,500 lbs dynamic load. ISPM 15 certified for international shipment to NATO facilities.
Brewery Keg Pallets
Reinforced 48x40 pallets with raised-edge deck boards creating a retaining lip to prevent keg rolloff. Heavy-duty oak stringers rated to 3,800 lbs for a full load of half-barrel kegs (165 lbs each, 20 kegs per pallet). Anti-slip coating on deck surface.
Solar Panel Shipping Pallets
Custom 72x42 inch pallets sized to carry standard 72-cell solar panels in vertical orientation. Notched stringers for pallet-jack entry on the long side. Foam padding strips between deck boards. 500-unit monthly recurring order with scheduled weekly delivery.
Retail Display Pallets
Sanded and stained 40x40 quarter-pallets for in-store product displays. Client logo heat-branded on all four visible faces. Clear polyurethane finish for a professional retail appearance. Designed to be the display — not hidden behind product.
Automotive Parts Bins
48x45 inch block pallets with pallet collar compatibility. Three-collar-high configuration creates a reusable parts bin for engine component storage. Block construction allows 4-way forklift entry. 1,200-pallet initial order with 200/month ongoing.
Pharmaceutical Clean Pallets
New SYP pallets with kiln-dried lumber (below 10% moisture), planed deck surfaces, and food-grade epoxy sealant. Each pallet individually shrink-wrapped after production for contamination-free storage. Full traceability documentation with lot numbers and moisture certificates.
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