Customers have requirements that don’t fit the standard output of plastic pallets and boxes. When this occurs, the customer has several options

• • Source a 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 need has already been made and may only require a Minimum Order Quantity (MOQ) to manufacture. As we represent many 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 rarely an option unless very large quantities are involved, because injection-moulding plastic pallets and boxes is expensive. 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 (1200 x 1000 mm) 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 guide manual loading. This ensured that when transferred across to the timber pallet, it was centred correctly.
    • Another customer wanted a lightweight pallet in the production area to move their product around, transfer it seamlessly outside the production area, and keep the lightweight pallet.
      We attached an aluminium box section to the pallet so the forks could go between the pallet and the product, removing only the product from the production area. We retested the modified pallet in accordance with ISO 8611.
    • In this instance, our customer used cardboard to divide their product on their standard hygienic plastic pallet, but they needed 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 a surface that was easy to clean.
      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 for protection.
      We connected two 1200x1000x760mm pallet boxes by cutting and welding the plastic, then added metal reinforcement for extra support. We also cut and welded a lid to match the box’s new size.

4 – Change the requirement from plastic to aluminium

Depending on the quantity, aluminium may be a more cost-effective option than plastic. When you adapt plastic, labour costs go 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 review both and decide 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. Evaluate this alongside the cost of manufacturing the non-standard pallet/box.

Summary

As you can see, several options are available; finding the best fit comes down to 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!