Standard pallets or custom-made ones? How to choose pallets suited to the nature of the load and the method of transport
“I have a machine measuring 1400 × 900 mm – which pallet should I choose?” This is one of the most common questions we hear from customers. The answer is rarely obvious, because the choice between a standard and a custom-made pallet depends not only on the dimensions of the load, but also on its weight, the method of transport, the phytosanitary requirements of the destination market and – something often overlooked – the method of storage at the recipient’s premises. A poorly chosen pallet not only risks damaging the goods, but also leads to wasted container space and higher freight costs. In this article, we show you how to approach this choice methodically.
Standard pallets – when they work best
EPAL 1200 × 800 mm – European standard
The EPAL (EUR) pallet, measuring 1200 × 800 mm, is the most widely used wooden pallet in Europe and one of the most versatile logistics carriers in the world. Its key advantage is its full compatibility with European racking, warehousing and transport systems. The standard dimensions of a 20′ shipping container (internal approx. 2350 × 5900 mm) allow 11 EPAL pallets to fit on a single layer – this is the optimal layout for minimising wasted space.
EPAL is ideal when the load fits within the pallet (does not protrude beyond the edges), the weight does not exceed 1,500 kg (the static load capacity of an EPAL pallet is 4,000 kg, and the dynamic load capacity is 1,500 kg), the recipient uses standard EUR storage systems, and the goods are shipped in a standard-sized shipping container, on a lorry flatbed or in a standard-sized railway wagon. Under these conditions, the EPAL pallet is the cheapest and most readily available solution – its price is lower than that of a custom-made pallet, and it is available immediately.
ISO 1200 × 1000 mm – the standard for non-European markets
The 1200 × 1000 mm ISO pallet is the standard in Asian, Australian and, to some extent, American markets. It is 200 mm wider than the EPAL, providing additional loading space and better compatibility with 40’ containers (internal dimensions approx. 2350 × 12030 mm), in which ISO pallets fit with less space wasted than EPAL pallets. For exports to Asian markets – particularly to China, Japan and Korea – the 1200 × 1000 mm pallet is often required by customers due to the racking standard used in their warehouses.
At Danpol, we manufacture pallets in both the EPAL 1200 × 800 mm and ISO 1200 × 1000 mm standards – both made from ISPM 15-certified timber, with the IPPC mark permanently and legibly printed on them. The choice of standard depends on the target market, the customer’s requirements and the type of container. If the customer has no preference, we recommend EPAL for Europe and the Middle East, and ISO 1200 × 1000 mm for Asia, Australia and North America.
Other standard sizes: industrial 1200 × 1200 mm and half-pallet 800 × 600 mm
The 1200 × 1200 mm pallet is primarily used in the chemical and food industries, where the square loading area facilitates the palletising of drums, IBCs and big bags. The 800 × 600 mm half-pallet (known as a display pallet), on the other hand, is ideal for retail logistics – it serves as a display unit that goes directly to the sales floor without the need for reloading. Both formats are less common in industrial exports, but it is worth being aware of them when designing a supply chain.
Custom-made pallets – when a standard pallet isn’t enough
Oversized loads
Every manufacturer of industrial machinery and components is familiar with situations where a load does not fit onto any standard pallet. A hydraulic unit measuring 1600 × 1100 mm, a control cabinet 1000 mm deep, a turbine with a diameter of 1800 mm – these components require custom pallets, designed to specific dimensions. Placing such a load on an EPAL pallet would result in a dangerous overhang, which destabilises the load unit and prevents safe stacking.
We design pallets in any size – from a minimum of 400 × 400 mm (for lightweight electronic components) to oversized platforms exceeding 3000 mm in length (for steel structural components, machine frames and profiles). Each custom-made pallet is manufactured from ISPM 15-certified timber, with the option of reinforcement using steel fittings, machine screws and additional stringers for heavy loads.
Heavy loads with an uneven distribution of weight
A standard EPAL pallet has a dynamic load capacity of 1,500 kg and is designed for evenly distributed loads. With heavy loads – exceeding 1,500 kg or with an uneven weight distribution – a standard pallet may bend, break or lose stability when handled by a forklift. In such cases, we design custom-made reinforced pallets with thicker deck boards (min. 25 mm instead of the standard 18–22 mm), triple stringers, steel reinforcements and a base adapted to the fork spacing of the specific forklift type.
A case study from our practice: a 2,800 kg MV transformer with an offset centre of gravity. A standard pallet was out of the question – we designed a platform measuring 1800 × 1400 mm with asymmetrical reinforcement: thicker stringers under the heavier section, steel corner fittings and skids adapted to the port crane’s forks. The pallet survived sea transport to Dubai without any deformation.
Specific logistics and transport requirements
The dimensions of the pallet should take into account not only the dimensions of the load, but also how it will be transported and handled throughout the journey. In container transport, it is essential to match the pallet to the internal dimensions of the container in order to maximise space utilisation and minimise the need for additional securing. A well-chosen pallet allows the cargo to be stowed in the container without any empty spaces that would need to be filled with dunnage. We pay particular attention to this when stowing containers – every centimetre of unused space is a potential area where the cargo could shift during sea transport.
In air freight, on the other hand, the weight of the pallet is crucial. Every kilogram of the pallet directly affects the freight cost (rates of 3–8 EUR/kg). That is why, for air freight, we design pallets from waterproof plywood or thin boards (12–15 mm), with minimal reinforcements – sufficient for safe handling on the cargo ramp, but up to 40–50% lighter than pallets intended for sea transport. This optimisation generates freight savings amounting to thousands of euros when producing a batch of several dozen pallets.
How to choose a colour palette – a practical decision-making guide
The choice of pallet should not be left to chance. At Danpol, we take a systematic approach based on five key parameters, which we analyse for every order. Below, we describe each of them – with examples to help you assess for yourself which pallet you need.
Criterion 1: Dimensions and weight of the load
Basic rule: the load should not protrude beyond the edges of the pallet. Ideally, the pallet’s dimensions should be 50–100 mm larger than the load’s outline when viewed from above. If the load fits on an EPAL pallet (1200 × 800 mm) whilst maintaining this margin, and its weight does not exceed 1500 kg, a standard pallet will suffice. If not, a custom-sized pallet is required.
For loads weighing over 1,500 kg or with an uneven distribution (where the centre of gravity is more than 15% of the pallet’s length away from its geometric centre), a standard pallet will not ensure safety. In such cases, we design a reinforced pallet, with calculated stringer spacing, board thickness and reinforcement methods. In the case of oversized loads – exceeding 2400 mm in any dimension – the pallet effectively becomes a transport platform and requires a bespoke design.
Criterion 2: Mode of transport
Sea transport requires structurally robust pallets – capable of withstanding a voyage lasting several weeks, port handling operations and the dynamic forces resulting from the ship’s rolling motion (accelerations of up to 0.8 g in the lateral direction). Pallets must be ISPM 15 certified with an IPPC stamp. Deck boards must be at least 18 mm thick, with solid timber stringers of at least 75 × 75 mm cross-section for loads exceeding 500 kg.
Air freight prioritises low pallet weight – every kilogram counts. We use thinner boards (12–15 mm), slats with a smaller cross-section and lighter reinforcements. Road transport within Europe offers the greatest flexibility – pallets do not need to be ISPM 15 certified (provided the goods do not leave the EU), and the strength requirements are lower than for sea transport. Regardless of the mode of transport, the pallet forms part of the export packaging system and should be selected in conjunction with the other load-securing components.
Criterion 3: Target market and phytosanitary requirements
Exports outside the EU require ISPM 15-certified pallets bearing the IPPC stamp. Some markets have additional requirements: Australia requires bark-free timber (DB code), the United States accepts only HT heat treatment (not MB fumigation), and Asian markets (Japan, Korea) may require additional documentation confirming treatment. For intra-EU exports, an ISPM 15 certificate is not required, but we recommend certified pallets if there is a possibility of re-exporting the goods outside the EU.
Criterion 4: Handling and storage methods
How will the pallet be handled throughout the route? A forklift requires an appropriate fork width and height (min. 90 mm). Lifting by crane – dedicated lifting points or fittings allowing slings to be attached. Manual handling – low total weight. Stacking – a pallet capable of withstanding a load from above without deformation. Each of these parameters affects the pallet’s design and should be taken into account at the design stage.
It is also important to consider what happens to the pallet once it reaches the recipient. If it is placed on a shelving system, its dimensions must be compatible with the shelves. If it is stored outdoors, the wood should be weather-resistant or treated. If it enters a pallet pool system, it must meet the requirements of the relevant operator.
Criterion 5: Economics – pallet cost vs risk cost
A custom-made pallet is more expensive than a standard one – usually by 30–80%, depending on the complexity of the design. But the cost of the pallet is a fraction of the cost of the load it carries. A transformer worth €200,000 on a €150 pallet – saving €50 on a cheaper standard pallet makes no sense if it increases the risk of damage to the load or rejection at the border. We recommend a simple rule: if the value of the load exceeds €10,000, the pallet should be selected individually, rather than ‘at a guess’ from a standard range.
What we use to make pallets – materials and construction
The primary material is wood – readily available, durable and easy to work with. At our facility in Delowo, we have a wood drying kiln where we carry out heat treatment in accordance with ISPM 15 requirements. After drying, the wood is cut, planed and assembled into finished pallets. For loads requiring increased strength, we use steel fittings – corner fittings, stringer reinforcements and transport handles. For the heaviest loads, the pallet effectively becomes a transport platform, structurally similar to an open-top transport box – with full strength calculations and documented load-bearing capacity.
An alternative to solid wood is waterproof plywood (9–12 mm) – which is lighter, moisture-resistant and does not require ISPM 15 certification. Plywood pallets are ideal for air freight (low weight) and single-use applications (exports where the pallet does not need to be returned). The disadvantage is the higher cost of the material and lower resistance to point loads compared to solid wood. At Danpol, we select the material on a case-by-case basis – based on the weight of the load, the type of transport and the customer’s budget.
The most common mistakes when selecting pallets – based on our experience
In over 30 years of manufacturing pallets, we have seen hundreds of instances where the wrong choice of pallet has led to damage to goods, customs issues or unnecessary costs. Here are the most common mistakes:
Load protruding beyond the edges of the pallet (overhang). A component wider or longer than the pallet protrudes beyond its edges, which prevents safe stacking, increases the risk of damage during forklift handling and makes loading into a container difficult. If the load does not fit on a standard pallet, a custom-made pallet is the only safe solution.
A pallet that is too weak for a heavy load. Using a standard EPAL pallet with a dynamic load capacity of 1,500 kg to carry a load of 2,000 kg is asking for trouble. This can lead to the deck boards sagging, the stringers splitting, and a loss of stability when moving the load with a forklift. Consequences: damage to goods, accidents during handling, and claims costs many times higher than the price of a proper pallet.
A shipping pallet for air freight (and vice versa). A solid, heavy-duty wooden pallet with steel fittings – ideal for sea transport – weighs too much for air freight, where every kilogram counts. On the other hand, a lightweight plywood pallet designed for air freight will not survive a sea voyage lasting several weeks, with its humidity, salinity and dynamic loads. The mode of transport determines the pallet’s design.
Incompatibility with the recipient’s warehouse system. A customer sends goods on a 1200 × 1000 mm pallet to a recipient whose racking is designed for 1200 × 800 mm EPAL pallets. The result: the recipient has to manually reload the goods in their warehouse, which leads to costs and delays. Before selecting a pallet, it is worth asking the recipient about the pallet standard used in their logistics operations.
No ISPM 15 certificate on the export pallet. A surprisingly common mistake, particularly for companies making their first exports. A pallet without an IPPC stamp when travelling outside the EU = goods being held up at the border. The cost of fumigation at the destination port, storage, and delivery delays – these are costs that can easily be avoided by ordering certified pallets straight away.
Comparison: standard pallet vs custom-made pallet
| Parameter | Standard pallet (EPAL / ISO) | Custom-made pallet |
| Dimensions | Fixed (1200×800, 1200×1000) | Any – for cargo |
| Load capacity | Up to 1,500 kg (dynamic EPAL) | Designed for heavy loads (no limit) |
| Lead time | 1–3 days (in stock) | 3–7 days (production) |
| Price | Lower (mass production) | 30–80% higher |
| ISPM 15 | Available with certification | Available with certification |
| Container optimisation | Standard timetable | Designed to fit the container |
| Reinforcements | Standard | Steel fittings, bolts, additional side rails |
| Application | Standard loads, batches, reverse logistics | Non-standard, heavy and high-value cargo |
Frequently Asked Questions (FAQ)
From what quantity is it worth ordering custom-made pallets?
There is no minimum order quantity – we produce both single units (tailored to a specific load) and batches numbering in the thousands. For single pallets, the unit cost is higher (as it includes a bespoke design), but the cost-effectiveness stems from the pallet being tailored to the load, rather than the order volume. In practice: if the value of the load exceeds €10,000, a bespoke pallet is always economically viable.
Can custom-made pallets also be ISPM 15 certified?
Yes. Every pallet manufactured by Danpol – whether standard or made to measure – is made from wood that has been heat-treated in our kiln and marked with the IPPC stamp. ISPM 15 certification does not depend on the pallet’s dimensions, but on the treatment of the wood and the manufacturer’s accreditation.
How quickly can you fulfil an order for custom pallets?
We produce custom-made pallets within 3–7 working days, depending on the quantity and complexity of the design. Standard EPAL pallets are produced within 1–3 days. For regular customers, we maintain a stock of kiln-dried timber, which allows us to fulfil urgent orders on an express basis (24–48 hours).
Can I order a plywood pallet instead of a solid wood one?
Yes. We primarily manufacture waterproof plywood pallets for air freight (low weight) and for single-use applications. Plywood does not require ISPM 15 certification, which simplifies export procedures. The drawbacks are the higher cost of the material and lower resistance to point loads compared to solid wood.
How do you work out how many pallets will fit in a container?
It depends on the type of container and the dimensions of the pallet. A 20′ container (internal dimensions approx. 2350 × 5900 mm) can hold 11 EPAL pallets (1200 × 800 mm) or 10 ISO pallets (1200 × 1000 mm) in a single layer. In a 40′ container, this amounts to 23 or 20 pallets respectively. For custom-sized pallets, we calculate the optimal layout on a case-by-case basis to maximise the use of container space.
Do you also manufacture pallet collars and straps?
Yes. Pallet collars in standard EPAL sizes and made to measure – made from ISPM 15-certified timber. These collars allow you to create ‘crates’ from pallets by stacking layers on top of one another, which is a cost-effective alternative to a full shipping crate for lighter and smaller loads.
Summary
Choosing the right pallet is a logistical decision that affects load security, transport costs and the efficiency of customs clearance. A standard EPAL or ISO pallet is suitable for typical loads weighing up to 1,500 kg that fit within standard dimensions. A custom-made pallet is necessary for non-standard, heavy or particularly valuable components – where the cost of the pallet is negligible compared to the risk of damage to the goods.
At Danpol, we have been helping customers choose the right pallet for over 30 years – from standard EPAL and ISO pallets, through reinforced pallets for heavy loads, to oversized platforms. All made from ISPM 15-certified timber, from our production facility located near the ports of the Tri-City. Check out Danpol’s full range of services – pallets, crates, export packaging and container stowage, all under one roof.
Not sure which pallet to choose? Tell usabout your load – we’ll find the right solution. Get in touch– we’ll provide a quote within 24 hours.
