Real Applications. Custom Designs. Practical Solutions.
From everyday manufacturing and shipping to specialized material handling, explore real examples of how GreenLabel corrugated pallets are designed around the products they carry and the applications they serve.
Corrugated pallets designed for compatibility with autonomous material-handling equipment.
This photo was taken during initial testing. Following the test, we made a minor upgrade to the bottom deck at minimal additional cost. The revised design has been used successfully in the customer's operation ever since.
A specialized corrugated pallet designed to support a large packaged component, using extra-tall blocks and a reinforced top deck to accommodate the product's protective foam packaging.
The raised block design provides additional clearance beneath the load, while corrugated buildup on the top deck helps stabilize the packaged product and keep it positioned securely during handling.
A Department of Veterans Affairs supply operation uses Ecodek pallets to handle everything from stacked shipping cartons to large Gaylord bulk containers filled with CPAP machine supplies.
Featuring triple-wall top decks and die-cut bottom construction for pallet-jack access, these pallets replaced higher-priced stock pallets, delivering substantial purchasing savings while meeting everyday material-handling requirements.
Stacked brown doors on a heavy-duty corrugated pallet with custom support blocks and bottom boards inside a manufacturing facility.
Heavy-Duty Oversized Pallets for Door Manufacturing
Two door manufacturers use heavy-duty corrugated pallets designed to support large, oversized products, offering a cost-effective alternative to custom plywood pallets.
One design uses custom blocks with bottom boards, while the other features additional Ecodek blocks and an open bottom deck. Customer feedback highlighted the impressive strength and substantial savings compared with traditional heavy-duty plywood pallets.
Custom-width corrugated pallets designed to move entire shipments through standard pedestrian doorways using narrow pallet jacks, eliminating the need to break down loads for manual delivery.
Unlike wood pallets that often must be removed after delivery, the corrugated pallet can remain on-site for recycling. For one customer's school fundraising deliveries, this solution reduced delivery time by approximately 45 minutes.
Compact corrugated pallets designed for smaller retail displays, providing a stable platform while accommodating pallet-jack handling within a limited footprint.
Specially positioned runners provide clearance for pallet-jack forks while maintaining the strength and stability needed to support the display. The quarter-pallet design minimizes the floor space required in retail environments.
A specialized corrugated pallet deck designed for use with a scissor-lift pallet jack, allowing employees to raise palletized products to a comfortable working height during manual operations.
By adapting the pallet construction to the lifting equipment, the customer could perform manual tasks at an elevated height, reducing the need for repeated bending and improving workplace ergonomics.
A corrugated pallet used in chemical production to support both large bulk bags (Super Sacks) and stacked bags of material destined for the tire industry.
Designed for automated loading and conveyor handling, the pallet supports loads of approximately 2,000–3,000 pounds while eliminating wood splinters as a source of pallet-related product contamination.
Half-size corrugated pallets provide a compact, stable foundation for retail product displays, with custom-sized blocks designed to accommodate specific material-handling requirements.
The specialized block configuration allows the pallet to work with the customer's handling equipment while supporting a fully loaded, multi-tier display in a smaller footprint than a standard pallet.
An integrated corrugated pallet and pre-glued infold tray used to support bulk containers. The trays ship nested with their sides folded down and are easily assembled during setup.
When a new customer required push-pull handling, GreenLabel added a scored corrugated extension to the bottom deck, allowing the existing design to accommodate slip-sheet equipment while retaining conventional forklift and pallet-jack access.
Round corrugated pallets designed to accommodate circular products and displays, providing practical solutions for retail environments and industrial shipping applications.
For retail displays, rounded pallet edges eliminate protruding corners that can create tripping hazards. For large industrial rolls, the circular design allows loads to be positioned closely together during shipping, reducing open space and the need for additional protective packaging.
Light-Duty Pallets for Seasonal Retail Distribution
Light-duty corrugated pallets featuring double-wall top decks, designed for high-volume seasonal shipments to a major big-box retail chain.
By matching the pallet construction to the application's requirements, GreenLabel provided an economical solution without unnecessary heavy-duty materials. Thousands of these pallets were shipped for holiday retail distribution.
Let's Talk About What You're Shipping.
Tell us what you’re shipping and we’ll design a corrugated pallet built around your product, your operation, and the way it moves.
