• Source non-standard size
• Develop a new tool to make a specific plastic pallet/box
• Adapt existing pallet/box to suit customer requirements
• Change the requirement from plastic to aluminium
• Change process to fit standard plastic pallet/box

1 – Source non-standard size

Sometimes the size you are looking for has already been made and may just require a Minimum Order Quantity (MOQ) to manufacture. As we represent a large number of manufacturers, we can quickly find a fit for you if available.

2 – Develop a new tool to make the specific plastic pallet/box

This is very rarely an option unless very large quantities are involved, due to the high cost of tooling for the injection moulding of plastic pallets and boxes. You would need at least 50,000 pieces to even consider this option.

3 – Adapt existing pallet/box to suit customer requirements

Most non-standard requests come in for small quantities to fit a specific function within a company’s process. From the most basic level, we have added wheels to pallets and boxes, all the way to cutting and joining two pallet boxes to create a large 2000x1200x760mm double pallet box.

Some examples of what we have done are;

• Our customer was automatically transferring from a plastic pallet (1200x1000mm) onto a timber pallet for export. The plastic pallet was packed manually, and the customer wanted it stacked in line and centred with the timber pallet it was to be transferred to.
  Our solution was to weld 4 corners onto the plastic pallet to give a guide for where the pallet was to be loaded manually. This ensured that when transferred across to the timber pallet, it was centred correctly.
  
• Another customer’s problem was that they wanted a lightweight pallet in the production area to move their product around, transfer it seamlessly to outside the production area, and keep the lightweight pallet.
  We attached an aluminium box section to the pallet to allow the forks to go between the pallet and the product, removing only the product from the production area. The modified pallet was retested in accordance with ISO 8611.
  
• In this instance, our customer was using cardboard to divide their product on their standard hygienic plastic pallet, but there was a requirement to remove the cardboard from a specific area of the site.
  Our solution was to weld solid plastic cross-sheets onto the plastic pallet, making it easier to clean and more robust.
  
• Our customer was constantly losing the cardboard inserts for their plastic EuroNorm boxes. They also wanted an easily cleanable surface.
  We replaced the cardboard inserts with plastic inserts and welded the new insert to the box.
  
• Our customer wanted to fit an oversized product into a pallet box to protect it.
  We connected two 1200x1000x760mm pallet boxes by cutting and welding the plastic, then provided additional support with metal reinforcement. A lid was also cut and welded to match the box’s new size.
  

4 – Change the requirement from plastic to aluminium

Depending on the quantity, it may be a more cost-effective option to use aluminium instead of plastic. When you are adapting plastic, there are labour costs beyond standard manufacturing costs. If you are considering a larger quantity, aluminium might be more cost-effective. It is not possible to apply a cut-off figure here, as it depends on the type of pallet/box you are looking for. The best option is to look at both and evaluate from there.

5- Change process to fit standard plastic pallet/box

In rare instances, the best option is to change your process to suit the standard plastic pallet/box. This has to be evaluated alongside the cost of manufacturing the non-standard pallet/box.

Summary

As you can see, there are several options available; finding the best fit is a matter of evaluating them. Feel free to contact AIC Plastics with questions.

Find out how AIC Plastics can help you find the right-sized plastic pallet or box for your business needs.

Call +353 (0)23 8847333 or email sales@aicplastics.com today!