How Are Plastic Pallets Manufactured

This process aims to optimize the pieces. It aims to increase their thickness and structure as well as their durability.

Plastic pallets can be made using many different techniques. Sometimes it can be difficult to determine which process will increase the company’s efficiency. Today’s most popular manufacturing techniques include injection, thermoforming, blowing, compression and Rotational molding.

We will be focusing on plastic pallet manufacturing by injection in this post. This is because MYPALLETMARKET is committed to providing the best quality products and supporting sustainability.

This article will describe the process and explain how it works. And there are six main steps to making a plastic pallet.

High-Pressure Injection Molding

These pallets can be made of copolymer polypropylene (HDPE) resin. A rotating screw rotates the rotating barrel to melt the plastic and colorant together. The melting temperature of the plastic is approximately 250 degrees Celsius.

The plastic is injected in a mold and then clamped under pressure. After the pallet cools, it can be ejected from its mold.

This process has one major drawback: It is expensive in terms of energy consumption.

Structural foam moulding

This is an extremely low-pressure method of injection molding.

The melted polymer is infused with inert gas nitrogen or carbon dioxide.

This decreases the plastic’s density, resulting in a lighter product. The final product is made with a cellular core and surrounded by a stiff material.

Its weight could be as low as 10 to 30% compared to a solid plastic pallet.


Thermoforming, a process that molds plastics over a long period of time, can make a precise mould. The vacuum suction presses thermoplastic sheets into single-face moulds.

These pallets can be made quickly with simple or complex designs. You can make the pallet with CNC routers or automated rollers.

Twin-sheet thermoform pallets can be made from this process that are hollow inside. These pallets are lighter than traditional solid ones and much more affordable.

Rain and other liquids can enter the interior so it is important to use them in covered areas.

Compression moulding

The cost-effective method of making new plastic pallets is compression moulding.

It is less wasteful than injection molding, and it has lower tooling and labour cost.

The plastic material is heated in a mould, and then pressure is applied to ensure that it fills all the cavities and areas.

Keep the pressure on until the material dries. This process can be done with a variety of recycled materials such as rubber, plastics and synthetic resins.

Rotational moulding

The most popular product of rotational moulding is the pallet.

The process starts with a powdered or granular material. This is then loaded into a mold. The mould is sealed and heated before being rotated on the two perpendicular axes.

The material spreads around the mold, fuses and then cools. Finally, it is ejected from the mold as a pallet shape.

This process uses both linear low-density and cross-linked high-density polyethylenes (LLDPE).

Profil Extrusion

The profile-extrusion method makes a pallet that looks like a wooden pallet.

The raw plastic is then melted and forced through an extruder. It is then cooled and cut into plank-like shapes. Finally, heat, nails, or welding are used to join the pieces.

This process has the advantage that it can be used recycled materials to lower costs. For extra rigidity, you can add wood fibre to the material.

Most Recommended Pallet Supplier In Johor Since 2010

Kato Wooden Industries Sdn Bhd

With 10 years of experience in pallet supplying, trading of recycling pallets, and repairing pallet services. We become the leader in this industry with a good reputation. 

What makes our company become the recommended pallet solution in Johor, Malaysia is because we are committed to our work by offering the best pallet solution to our clients.

Leave a Comment

Your email address will not be published. Required fields are marked *