Custom Pallets
When off-the-shelf does not fit, we engineer and build pallets around your exact requirements. Unusual dimensions, extreme load ratings, specialty materials, branded surfaces, or complex multi-level configurations—if it can be built from wood, we can build it for you.
Describe Your Custom Pallet
Share your dimensions, load requirements, and use case. Our team will design a solution and provide a detailed quote with lead time.
Why Go Custom?
Standard pallets work for standard loads. But when your product, your process, or your logistics demand something different, a custom pallet eliminates compromise and maximizes efficiency.
Non-Standard Dimensions
Your product does not fit a 48x40. Maybe you need a 60x48 for oversized machinery, a 24x24 for small component kits, or a 96x48 for long structural steel. We build any dimension that physics allows.
Heavy-Duty Load Ratings
Standard pallets top out around 2,500 to 3,000 lbs dynamic load. If you are moving engine blocks, concrete products, or industrial equipment, we engineer pallets rated for 5,000 lbs and beyond using heavier stringers and reinforced deck boards.
Branded Pallets
Turn your pallet into a branding opportunity. We offer stenciled company logos, color-coded deck boards, and printed messages. Branded pallets are popular for trade shows, retail displays, and companies that want brand consistency down to the last mile.
Specialty Materials
Need a pallet that resists moisture? We can build with treated lumber or incorporate composite materials. Need fire-resistant properties? We offer flame-retardant treated wood. Chemical-resistant applications are addressed with sealed or coated surfaces.
Automation Compatibility
Robotic palletizers and automated storage/retrieval systems demand pallets with extremely tight dimensional tolerances. We manufacture to plus or minus 1/8 inch consistency, with options for RFID tags, barcodes, and uniform weight specifications.
Multi-Level & Nested Designs
Some products require multi-tier pallet systems with built-in dividers, cradles, or nesting features. We design configurations that secure oddly shaped items during transit, reducing damage rates and eliminating the need for excessive internal packaging.
Our Custom Design Process
From initial conversation to delivered pallets, here is how we turn your requirements into a production-ready design. Most custom projects move from inquiry to first delivery in under two weeks.
Consultation & Requirements Gathering
We start with a conversation about what you are shipping, how it is being handled, where it is going, and what your budget looks like. The more detail you can share, the better we can engineer a solution. If you already have a spec sheet or drawing, even better—send it over and we will review it.
Engineering & Design
Our team designs the pallet based on your requirements. We determine the optimal lumber species, board dimensions, fastener types, and configuration. For heavy-duty or complex designs, we calculate load distribution to ensure every stringer and deck board is appropriately sized for the forces it will experience.
Prototype & Approval
For first-time custom orders, we build a small prototype batch (typically 5 to 10 pallets) for you to test in your actual operation. This allows you to verify fit, fork engagement, racking compatibility, and load handling before committing to a full production run. We refine the design based on your feedback.
Production
Once the design is approved, we move to full production. Our assembly team builds each pallet using jigs and fixtures that ensure consistency across the entire run. Quality checks are performed at regular intervals throughout production.
Delivery & Ongoing Supply
Finished pallets are delivered to your facility on our trucks or available for pickup at our Eugene yard. For recurring custom orders, we maintain your specifications on file so reorders are fast and consistent. Many of our custom clients set up scheduled delivery programs for predictable supply.
Industries We Serve with Custom Pallets
Aerospace & Defense
Oversized, anti-static, and MIL-SPEC packing
Agriculture & Wine
Harvest bins, barrel pallets, vine crate bases
Automotive & Manufacturing
Engine cradles, parts kitting, heavy assembly
Construction & Building
Lumber bunks, brick pallets, tile platforms
Electronics & Technology
ESD-safe, clean room, precision-dimensioned
Food & Beverage
FDA-compliant, HT, sanitary construction
Healthcare & Pharma
Clean, traceable, temperature-controlled
Retail & E-Commerce
Display-ready, branded, quarter-pallets
Custom Pallet FAQ
What is the minimum order for custom pallets?
Our standard minimum for custom orders is 25 pallets. This allows us to set up jigs and fixtures cost-effectively. For very complex designs, minimums may be higher. Contact us to discuss your specific needs.
How long does a custom order take?
Typical lead time is 5 to 14 business days depending on complexity, lumber availability, and current production schedule. Prototype batches can often be turned in 3 to 5 days. Rush service is available for an additional fee.
Can you match a pallet we are currently using from another supplier?
Absolutely. Send us a sample or detailed measurements and photos, and we will reverse-engineer the design. We can match it exactly or suggest improvements based on what we see.
Do you offer heat treatment on custom pallets?
Yes. All custom pallets can be heat treated to ISPM-15 standards and stamped with our certification mark. This is included as a standard option in our quoting process.
Can you add RFID tags or barcodes?
We can incorporate RFID tags into the pallet structure during manufacturing. We also offer barcode labels and stenciled identification numbers for inventory tracking purposes.
What if I only need a few custom pallets?
For very small quantities (under 25), we can still help. The per-unit cost will be higher due to setup, but we never turn away a project based on size alone. Reach out and we will see what we can do.
Custom Pallet Case Studies
Real projects, real results. Here are examples of custom pallet solutions we have engineered for West Coast businesses across a range of industries.
Willamette Valley Winery
Challenge
Needed a pallet that could securely transport 60-gallon oak wine barrels (540 lbs each, 4 barrels per pallet) without rolling or shifting. Standard flat pallets caused barrels to roll during forklift transport and truck transit, resulting in breakage and costly wine loss.
Our Solution
Designed a 48" x 48" hardwood pallet with built-in barrel cradles routed into the top deck boards. Four semi-circular channels hold barrels securely without any additional blocking or strapping. Lead boards were reinforced with doubled lumber to handle the 2,160 lb concentrated load.
Result
Barrel damage during transport dropped from 3.2% to 0.1%—a 97% reduction. The client saved over $28,000 in the first harvest season by eliminating breakage, and the cradle pallets are reused across 15+ cycles.
Pacific Northwest Electronics Manufacturer
Challenge
Their automated warehouse system required pallets with tolerances tighter than standard production. The AS/RS (Automated Storage and Retrieval System) would jam if pallet dimensions varied by more than 1/8 inch, and existing suppliers could not consistently deliver to spec.
Our Solution
Built 48" x 40" Douglas Fir pallets on precision jigs with automation-grade tolerances: plus or minus 1/8 inch on all dimensions, diagonal variance under 3/16 inch, and moisture content controlled below 19%. Every pallet was individually measured and stamped with a sequential serial number for traceability.
Result
AS/RS jam rate dropped from 4.7 jams per week to zero. System throughput increased by 12% due to eliminated downtime. The client now orders 500 pallets per month on a recurring delivery program.
Heavy Equipment Manufacturer (Southern Oregon)
Challenge
Shipping 8,000 lb industrial compressors on standard pallets was causing stringer failures and load shifting. The compressor footprint required a 60" x 60" platform, which was not available as a standard size from any local supplier.
Our Solution
Engineered a heavy-duty 60" x 60" pallet using 4x4 hardwood stringers (doubled at center span) with 6/4 red oak deck boards. Steel corner brackets were added for additional lateral rigidity. Anti-slip rubber pads were bonded to the deck surface. Load capacity rated at 10,000 lbs dynamic.
Result
Zero pallet failures across 14 months and 340+ shipments. Transit damage claims dropped from $45,000/year to under $2,000/year. The robust design also eliminated the need for separate crating, saving $85 per unit in packaging costs.
Regional Food Distributor
Challenge
Needed branded pallets for retail store deliveries where the pallet would be used as a floor display in grocery stores. The pallet had to be food-safe (HT treated, no chemicals), visually clean, and carry the distributor's logo visible from all four sides.
Our Solution
Manufactured 40" x 40" quarter-pallets from kiln-dried Douglas Fir with ISPM-15 heat treatment. Company logo was stenciled in food-safe ink on all four stringer faces. Deck boards were planed smooth and sanded to 120 grit for a retail-ready appearance.
Result
The branded pallets became a recognized part of the distributor's in-store presence. Retail partners reported that the professional presentation increased impulse purchases by 8% to 12% for products displayed on the branded pallets versus generic brown pallets.
Engineering Specifications We Work With
Custom pallets are engineered, not just built. Here are the key parameters we address in every custom design, and the range of specifications we can accommodate.
| Parameter | Standard Range | Extended (Custom) | Notes |
|---|---|---|---|
| Overall Length | 36" - 48" | 12" - 120" | Lengths over 60" require reinforced center stringers to prevent deflection |
| Overall Width | 36" - 48" | 12" - 72" | Widths over 48" typically use 4 or 5 stringers instead of the standard 3 |
| Pallet Height | 5" - 6.5" | 3.5" - 12" | Low-profile designs (3.5") available for container loading. Tall designs for conveyor systems. |
| Dynamic Load | 2,500 - 3,000 lbs | Up to 15,000 lbs | Loads over 5,000 lbs use doubled stringers, thicker deck boards, and/or steel reinforcement |
| Static Load | 5,000 - 6,000 lbs | Up to 30,000 lbs | Heavy static loads may require full-perimeter support or concrete block understructure |
| Deck Board Thickness | 5/8" - 3/4" | 1/2" - 1.5" | Thicker boards for heavy point loads. Thinner boards for weight reduction on light loads. |
| Stringer Dimensions | 2x4 nominal | 2x4 to 6x6 | Heavy-duty builds use 4x4, 4x6, or 6x6 stringers for extreme load capacity |
| Entry Points | 2-way or 4-way | 2-way, 4-way, or partial | 4-way entry requires notched stringers or block construction. Partial entry for specialized handling. |
| Fasteners | Ring-shank nails | Nails, screws, bolts, brackets | Screws and bolts for extreme vibration environments. Steel brackets for lateral load resistance. |
| Surface Treatment | Raw wood | Stencil, paint, seal, rubber, anti-slip | Coatings and treatments for branding, moisture resistance, or friction requirements |
Custom Pallet Material Selection Guide
Choosing the right materials is as important as the design itself. Use this chart to understand which materials solve which problems in custom pallet applications.
Douglas Fir (Softwood)
Strengths
- + Best strength-to-weight ratio
- + Locally sourced, fast delivery
- + Easy to work with and repair
- + Takes heat treatment well
Limitations
- - Lower impact resistance than hardwood
- - Not ideal for 30+ cycle pallet pools
Red Oak (Hardwood)
Strengths
- + Exceptional impact resistance
- + Very high load capacity
- + 25 to 30+ cycle lifespan
- + Superior nail holding strength
Limitations
- - Heavier weight (adds freight cost)
- - Higher material cost
- - Slower to heat treat
Treated Lumber
Strengths
- + Moisture and rot resistance
- + Extended outdoor lifespan
- + Insect and fungal protection
Limitations
- - Chemical treatment limits food use
- - Higher cost than untreated
- - Requires special disposal
Plywood Deck Boards
Strengths
- + Smooth, splinter-free surface
- + Consistent thickness
- + No gaps between boards
- + Excellent for automated systems
Limitations
- - Heavier than solid lumber
- - Edge delamination risk if wet
- - Not repairable
Composite / OSB
Strengths
- + ISPM-15 exempt (no HT needed)
- + Lightweight and consistent
- + No nail or splinter hazards
Limitations
- - Limited load capacity
- - Poor moisture resistance
- - Not repairable or recyclable
Hybrid (Wood + Steel)
Strengths
- + Extreme load capacity
- + Steel brackets prevent racking
- + Corner reinforcement for impacts
- + Can be engineered for any load
Limitations
- - Highest cost option
- - Heavier total weight
- - Requires metalworking capability
Custom Pallet Turnaround Timeline
How quickly can you get custom pallets? It depends on complexity, quantity, and materials. This timeline covers every stage from first contact to delivery for typical custom projects.
| Project Phase | Simple Custom | Standard Custom | Complex / Heavy-Duty | What Happens |
|---|---|---|---|---|
| Consultation & Quote | 1 day | 1 - 2 days | 2 - 3 days | We discuss your requirements, review drawings, and prepare a detailed quote with specs |
| Engineering & Design | 0 - 1 day | 1 - 3 days | 3 - 5 days | Pallet design is finalized using PDS software, materials are selected, and load calculations verified |
| Prototype Build | Optional | 2 - 3 days | 3 - 5 days | Small batch of 5 to 10 sample pallets built for your approval and on-site testing |
| Material Procurement | 0 days (in stock) | 1 - 3 days | 3 - 7 days | Specialty lumber, hardware, or treatment chemicals ordered if not in our standard inventory |
| Production | 2 - 3 days | 3 - 7 days | 5 - 10 days | Jigs are set, lumber is cut, pallets are assembled, QC inspections are performed |
| Treatment (if HT) | + 1 day | + 1 day | + 1 - 2 days | Heat treatment kiln cycle, cooling period, and ISPM-15 stamping |
| Delivery | 1 day | 1 day | 1 - 2 days | Loaded on flatbed or available for pickup. Multi-truck orders may ship in stages. |
| Total Lead Time | 5 - 7 business days | 7 - 14 business days | 14 - 25 business days | End-to-end from first contact to pallets at your dock |
How to Expedite Your Custom Order
Provide Complete Specs
The more detail you provide upfront—dimensions, load weights, handling method, destination, and quantity—the faster we can move through the engineering phase. A dimensioned drawing eliminates days of back-and-forth.
Skip the Prototype
For simple custom orders (non-standard dimensions with standard construction), you can skip the prototype phase and go straight to production. This saves 2 to 5 days but means the first delivery is your production run. Best for experienced pallet buyers.
Rush Production Fee
Need it faster? We offer rush production for an additional fee (typically 15% to 25% premium) that moves your order to the front of our production queue. Rush orders can often cut total lead time by 30% to 50%.
Let's Build Your Perfect Pallet
Call (541) 396-8883 or visit us at 1875 W 6th Ave, Eugene, OR 97402 to discuss your custom project. No job is too unusual.