Is a Corrugated Pallet Right for Your Application?
The right pallet depends on more than load weight. Product footprint, handling equipment, storage, shipping conditions and the complete distribution environment all play a role.
GreenLabel evaluates the application first,
then designs the Ecodek pallet around it.
The Pallet Is Only One Part of the System
A pallet's performance depends on more than the pallet itself. We look at your entire application to ensure a corrugated pallet will work in your real-world environment.
Application Fit
What We Need to Evaluate Your Pallet
The more detail you can share, the faster we can determine if an Ecodek pallet is right for your application and recommend the best design.
Product & Load
Product type and packaging
Total load weight (max and average)
Load dimensions(L x W x H)
Footprint (Uniform or Varies)
Unit load configuration (boxes, bulk, etc.)
Handling & Distribution
Handling equipment (pallet jacks, forklifts, conveyors)
Storage Method (floor, racks)
Shipping Conditions (domestic, export, mode)
Number of Handling Cycles (one-way or reusable)
Any Special Requirements
Replacing an Existing Pallet?
Most customers are replacing an existing pallet, but the current pallet is only one piece of the evaluation. We look at the product, load, handling equipment, storage, shipping conditions and any design features that are important to your process.
Photos or dimensions of the current pallet can be helpful, but the new Ecodek design should be based on the application, not simply copied from what is already being used.
Testing & Validation
From Sample to Production
We test, validate and refine the pallet design so you can move forward with confidence.
1
Sample & Initial testing
GreenLabel can provide sample pallets for limited testing with the actual product and handling equipment.
2
Production Trial
Once the initial design looks right, GreenLabel produces a small trial quantity so the customer can run the pallets through normal production, shipping and handling.
3
Validation & Refinement
The customer evaluates the trial in the real application. If any issues or concerns come up, we make adjustments and repeat the process as needed before moving into regular production.
HANDLING & STORAGE
The Handling Environment Matters
A corrugated pallet does not operate by itself. How it is supported, moved, stored and exposed during distribution all affect the design. GreenLabel considers these conditions before recommending an Ecodek pallet.
Explore the technical details below.
Click any section to expand and learn more about Ecodek pallet design and construction.
Concentrated Loads & Support Geometry ▾
Total weight is only part of the equation.
A 1,000-pound load distributed across the pallet deck places very different demands on the pallet than 1,000 pounds concentrated onto a few small contact points.
Products with feet, legs, corners, drums or other concentrated loading points may require additional support or a different deck construction. GreenLabel evaluates both
how much the load weighs and where that weight enters the pallet.
Handling Practices & Intended Use ▾
Ecodek pallets are designed for normal forklift and pallet-jack handling, but they should be handled as intended.
Forks should be fully inserted before lifting, and handling equipment should enter the pallet squarely rather than striking the supports at an angle.
A pallet designed around one product and handling system should also be reviewed before being reassigned to a substantially different load or application.
Conveyor Support & Contact Points ▾
Conveyor type, roller spacing, chain locations and contact surfaces determine where the pallet is supported. GreenLabel evaluates these conditions when selecting the bottom configuration and support placement. Systems that leave critical areas unsupported may require a different design or another pallet material..
Rack Storage & Unsupported Spans ▾
Ecodek pallets should not be placed directly into unsupported open pallet racks.
Full solid decking provides the continuous support required and is suitable for corrugated pallets. Mesh decking can also work depending on the mesh configuration and the application.
Another option is to leave a conventional wood or plastic pallet in the rack position and place the loaded Ecodek pallet on top of it. The conventional pallet then acts as the supported floor beneath the corrugated pallet.
As with any change to a pallet or storage system, the completed application should be tested before full implementation.
Humidity, Dampness & Water Exposure ▾
Ecodek pallets are designed with normal warehouse humidity and shipping conditions in mind.
We also understand that trailers are not always perfectly sealed and floors are not always perfectly dry. A slightly damp trailer floor or incidental moisture during normal transportation is different from prolonged direct exposure to water or saturation.
If significant water exposure is expected as part of the normal application, that should be discussed during the design process.
Where Corrugated May Not Be the Best Fit
Corrugated pallets are exceptionally capable, but they are not the right solution for every application. They may not be the best fit when:
Various Loads
Applications where the pallet may carry different products, weights or footprints from shipment to shipment can be difficult to design around.
Open Rack Storage
Unsupported open racks are not suitable without a supported deck or platform.
Unsupported Handling Systems
Conveyors or equipment that leave critical portions of the pallet unsupported may not be a good fit.
High-Cycle Closed-Loop Systems
Applications where pallets are continuously recovered and reused for many cycles may be better suited to a more reusable pallet.
Prolonged Water Exposure
Normal humidity and incidental dampness are fine, but prolonged direct water exposure or saturation is not.
Many Limitations Have Solutions
Many apparent limitations can be addressed through proper support, pallet design, or a simple change to the surrounding handling system.
EXPLORE MORE
Find the Information You Need
ECODEK PALLETS
Overview of Ecodek corrugated pallets, benefits, capabilities & applications.
Design & Construction
See how Ecodek pallets are designed & built around the application.
Compare Pallets
See how corrugated pallets compare with traditional wood pallets.
Materials & Sustainability
Explore corrugated, cleanliness, recyclability & responsible sourcing.
Examples
Explore real-world Ecodek pallet applications across different industries.
Export Pallets
Learn how corrugated pallets simplify international shipping and ISPM-15 requirements.
CPG & Bulk Packaging
Explore pallet solutions for bottles, closures, trays, totes and bulk packaging.
Pricing
Learn what affects custom corrugated pallet pricing & how quotes are developed.
Frequently Asked Questions
Resources & FAQ
How do I know if a corrugated pallet is right for my application?
The best way to determine fit is to evaluate the complete application, including the load, handling equipment, storage, shipping conditions and how the pallet will be supported.
What information does GreenLabel need to evaluate a pallet?
Useful information includes the loaded weight, product footprint, pallet dimensions, stacking requirements, handling equipment, conveyor type, rack storage and shipping environment.
Can GreenLabel replace an existing wood or corrugated pallet?
Yes. The existing pallet can provide useful information, but the new design is based on what the application actually requires rather than simply copying the current pallet.
Do I need to send GreenLabel my existing pallet?
Usually not. Photos, dimensions and information about how the pallet is used are generally enough to begin evaluating the application.
Can Ecodek pallets be reused?
Yes, in some applications. Reuse depends on the pallet design, handling environment and condition of the pallet after each use.
Can corrugated pallets be used on conveyors?
Yes, when the conveyor supports the pallet in the areas designed to carry the load. Chain location, roller spacing and other contact points should be considered during pallet design.
Can corrugated pallets be stored in pallet racks?
Full solid decking provides the support corrugated pallets need. Mesh decking can also work depending on the configuration. Unsupported open racks are not suitable for direct Ecodek pallet storage.
What if my product has concentrated load points?
Products with feet, legs, corners or other small contact areas may require additional support or a different deck construction. GreenLabel evaluates where the weight enters the pallet, not just the total load.
Can corrugated pallets handle humidity or a damp trailer floor?
Yes. Normal humidity and incidental dampness are part of real-world shipping conditions. Prolonged direct water exposure or saturation is different and should be avoided.
Do you test the pallet before full production?
GreenLabel can provide sample pallets for initial testing. A small trial quantity can then be produced so the customer can run the pallets through normal production, shipping and handling before moving into regular production.
Still Have Questions? Let's Talk.
Tell us what you’re shipping and we’ll design a corrugated pallet built around your product, your operation, and the way it moves.