Introduction to Metal Pallets:
Metal pallets, commonly made from steel or aluminum, serve as a robust solution for material handling, offering a durable alternative to wood and plastic pallets.1 Produced in both flat and walled varieties [User Query], these pallets primarily facilitate the movement of heavy objects and optimize warehouse space [User Query]. Furthermore, metal pallets provide significant long-term value due to their superior strength and load-bearing capacity, extended lifespan, improved hygiene, and complete recyclability.3 These attributes position them as a strategic solution for businesses aiming to enhance efficiency and sustainability in their logistics operations.
Types, Designs, and Specifications of Metal Pallets:
Metal pallets are manufactured in a variety of designs, each tailored to meet the specific needs of different industries:
Rackable Pallets: Designed with runners or ledges, these pallets allow for safe placement in racking systems, thereby maximizing vertical storage space. They are engineered to withstand the weight and pressure of being placed on pallet rack beams.
Nestable Pallets: These metal pallets are designed to nest within each other when empty, significantly reducing the space required for storage and transportation in their empty state. This feature is particularly beneficial for industries with limited storage space or closed-loop transportation systems.
Foldable Pallets: Foldable metal pallets feature hinged or detachable side frames, allowing them to be collapsed for compact storage when not in use. This makes them highly suitable for industries with fluctuating storage needs or limited space.
Flat Pallets (Standard Iron Pallets): Serving as basic platforms for material handling, these pallets are often used with heavy-duty racking systems such as selective racks, double-deep racks, and drive-in racks. Their simple design allows for widespread use in various applications.
Pallets with Raised Surfaces: These types of pallets have raised surfaces or features that provide better support or handling capabilities for specific types of goods, preventing product damage.
Foldable Pallet Cages: Combining the functionality of a forklift platform and a container for storing goods, these pallets offer a dual-purpose solution. They often include locking mechanisms and foldable side panels, allowing for space-saving storage when not in use.
Stackable Pallets: Designed to be stacked on top of each other when either full or empty, these pallets maximize the use of vertical warehouse space. Some stackable designs include additional features like detachable side frames or foldability for increased flexibility.
Mesh Pallets (Mesh Box Pallets): Consisting of a pallet base and a steel frame structure, these pallets are used for loading and storing goods, providing visibility and protection for the contents.
Stillage Pallets: Similar to a pallet or skid but built with sides, these structures offer enhanced strength and stability for transporting specific loads.
In addition to the variety of types, the design of metal pallets also includes different features that enhance their efficiency and safety:
Entry Points: Pallets can have 2-way entry (access from two opposite sides) or 4-way entry (access from all four sides), which affects the ease of handling and transportation efficiency. Four-way entry pallets offer greater flexibility in handling.
Deck Types: The deck of metal pallets can be open metal planks , a complete deck without gaps, a corrugated deck, a perforated deck, or a solid sheet deck. The choice of deck type depends on the type of load and the need for ventilation or drainage.
Additional Features: Some pallets include additional features such as non-slip surfaces, forklift pockets, edge and corner protectors, detachable side frames, and foldability, which improve their functionality and safety. Some designs include anti-tipping bars and corner attachment points for secure transportation.
Furthermore, metal pallets can be customized to meet specific customer needs, including dimensions, surface finish, and special configurations.
Table 1: Types of Metal Pallets, Features, and Applications
Metal Pallet Type | Key Features | Common Applications |
| Rackable Pallets | With runners or ledges for safe racking | Warehouses with racking systems |
| Nestable Pallets | Designed to nest when empty | Closed-loop transport, space-limited warehouses |
| Foldable Pallets | With hinged or detachable side frames | Warehouses with variable storage needs |
| Flat Pallets | Flat surface, basic structure | General material handling, use with heavy-duty racks |
| Pallets with Raised Surfaces | Raised surfaces or features for better support | Transporting specific goods |
| Foldable Pallet Cages | Combines platform and container, with locks and foldable side panels | Secure storage and transport of goods |
| Stackable Pallets | Can be stacked when full or empty | Optimizing vertical warehouse space |
| Mesh Pallets | Pallet base with steel mesh frame | Loading and storing goods with visibility and ventilation |
| Stillage Pallets | Similar to pallets with custom walls or supports | Transporting and storing specific and bulky loads |
Standard Dimensions and Load Capacity:
Metal pallets are produced in standard dimensions that vary depending on the geographical region and industry of use:
North American Standard: The most common size is 48 by 40 inches (1219 by 1016 mm), often referred to as the GMA pallet. Other common sizes include 42 by 42 inches and 48 by 48 inches. The military uses a 40 by 48 inch standard. A size of 44 by 40 inches is also mentioned as a US military standard.
European Standard (EUR/EPAL): The standard size is 1200 by 800 mm (47.2 by 31.5 inches), regulated by the European Pallet Association (EPAL). Other Euro pallet sizes such as EUR 2 (1200 by 1000 mm) and EUR 6 (800 by 600 mm) also exist.
Asian Standard: Common sizes include 1100 by 1100 mm and 1200 by 1000 mm.
Australian Standard: The typical size is 1165 by 1165 mm.
ISO Standards: The International Organization for Standardization (ISO) recognizes six standard pallet sizes to facilitate international compatibility, with dimensions ranging from 1016 by 1219 mm to 1165 by 1165 mm.
The load-bearing capacity of metal pallets depends on their design, dimensions, and the type of steel used in their construction. Generally:
The static load capacity (when stationary) of metal pallets often exceeds 2722 kg (6000 lbs) and can reach 4536 kg (10000 lbs) or more. Some heavy-duty pallets can handle up to 13600 kg (30000 lbs) of static load. Some models have a static load capacity of 7 tons.
The dynamic load capacity (during movement) typically ranges from 1134 kg (2500 lbs) to 2268 kg (5000 lbs). Some can handle 3 tons of moving load.
The racking load capacity can reach 2268 kg (5000 lbs).
Euro pallets can handle up to 1500 kg of moving load and 4000 kg of static load. Some aluminum Euro pallets can carry 1000 to 2000 kg.
Stackable steel pallets can have a load capacity of up to 1000 kg and be stacked up to four high. Some steel pallet boxes can handle 1500 kg when stacked up to four high.
One source mentions a load capacity of 5 tons for stackable transport steel pallets.
Dimensions and design features such as reinforced edges and additional support beams can significantly impact the load-bearing capacity of metal pallets.
Table 2: Standard Dimensions and Load Capacity of Metal Pallets by Region
Region | Pallet Size (Length x Width x Height) (mm) | Pallet Size (Length x Width x Height) (inches) | Static Load Capacity (kg) | Static Load Capacity (lbs) | Dynamic Load Capacity (kg) | Dynamic Load Capacity (lbs) | Racking Load Capacity (kg) | Racking Load Capacity (lbs) |
| North America | 1219 x 1016 x 121 | 48 x 40 x 4.75 | 3629 - 13608 | 8000 - 30000 | 1814 - 2268 | 4000 - 5000 | 998 | 2200 |
| Europe (EUR/EPAL) | 1200 x 800 x 144 | 47.2 x 31.5 x 5.7 | 1500 - 4000 | 3307 - 8818 | 1000 - 1500 | 2205 - 3307 | - | - |
| Asia | 1100 x 1100 x 150 | 43.3 x 43.3 x 5.9 | - | - | - | - | - | - |
| Australia | 1165 x 1165 x 165 | 45.9 x 45.9 x 6.5 | 2000 | 4409 | 2000 | 4409 | - | - |
Manufacturing Process of Metal Pallets from Steel Sheet:
The production of metal pallets from steel sheets involves several stages carried out with precision and expertise:
Material Preparation:
Steel coils or sheets are received and inspected for quality and specifications. POSCO-produced sheets are noted for their high quality.
The steel is then cut to the required dimensions at room temperature using shearing machines. Alternative cutting methods such as high-temperature gas cutting, plasma cutting, and laser cutting exist but may have drawbacks like higher production costs or difficulties in finishing work. Laser cutting offers high precision and efficiency for cutting metals of various thicknesses. CNC plasma laser cutting equipment allows for precise and clean cuts.
The corners of the cut sheets are shaped using press machines and specific molds. Grinding equipment can also be used to remove burrs resulting from corner cutting.
Shaping and Forming:
The cut steel sheets undergo a straightening and correction process using roll press machines to ensure flatness. This process may involve multiple rolling stages in both length and width directions.
For some designs, roll forming machines are used to create specific profiles for pallet components such as columns and plates.
Assembly and Welding:
The formed components are assembled according to the pallet design.
Welding is a critical step, often performed using CO2 gas-shielded welding to create strong and uniform joints. Common welding methods include MIG (Metal Inert Gas) and TIG (Tungsten Inert Gas) welding, chosen based on material thickness and desired weld quality. Robotic welding systems enhance efficiency and consistency in mass production. Spot welding is also used for some assembly stages.
Surface Finishing:
Preparation: Steel pallets are typically subjected to pickling and phosphating processes before painting to clean the surface and improve paint adhesion. Sandblasting can also be used to remove impurities and create a suitable profile for better coating adhesion.
Painting and Powder Coating: Powder coating involves applying electrostatically charged powder particles and baking them with heat, resulting in a durable and corrosion-resistant finish. Different colors can be used for identification or aesthetic purposes.
Galvanizing: To enhance rust resistance, pallets can undergo hot-dip galvanizing (immersion in molten zinc) or electro-galvanizing (applying a zinc coating through electrolysis). Hot-dip galvanizing provides a thicker and more durable zinc layer.
Final Inspection and Packaging: The finished pallets undergo quality inspection for dimensions, weld integrity, and surface finish. They are then typically packaged and prepared for shipment.
Types of Steel Used in the Construction of Metal Pallets:
Various types of steel are used in the construction of metal pallets, each with unique properties:
Carbon Steel:
Composed mainly of iron and carbon, with small amounts of other alloying elements.
Available in low-carbon (mild steel), medium-carbon, and high-carbon grades, each offering a different balance of strength, hardness, ductility, and weldability. Low-carbon steel (0.05-0.25% carbon) is cost-effective and has high ductility and weldability. Medium-carbon steel (0.30-0.50% carbon) offers a balance between strength and toughness. High-carbon steel (0.60-1.00% carbon) has high hardness but low ductility.
The strength, durability, and affordability of carbon steel make it a common choice for metal pallet construction.
Specific grades like A36, 1020, and 1045 are frequently used in structural applications. Mild steel (low-carbon steel with less than 0.25% carbon) is typically used in pallet construction.
Stainless Steel:
The presence of chromium (at least 10.5%) in its composition provides excellent resistance to corrosion and rust. The addition of molybdenum can further enhance corrosion resistance, especially in chloride-rich environments.
Various grades of stainless steel exist, including austenitic (300 series like 304 and 316), ferritic (400 series), martensitic, and duplex, each with specific properties and applications.
Ideal for industries with strict hygiene requirements such as food and pharmaceuticals due to its non-porous nature, lack of dust generation, and ease of cleaning.
Advanced High-Strength Steel (AHSS):
A new generation of steel alloys offering a unique combination of durability, ease of manufacturing, and high strength-to-weight ratio, suitable for demanding applications like the automotive industry.
Includes Dual Phase (DP), Transformation-Induced Plasticity (TRIP), and Martensitic steels, each with unique properties and used particularly in the automotive industry for weight reduction and improved crash performance.
Aluminum:
A strong yet lightweight metal often used in aerospace, outdoor storage, and military transport. Offers good durability and corrosion resistance.
Diverse Applications of Metal Pallets in Various Industries:
Metal pallets, due to their unique characteristics, have a wide range of applications across various industries:
Warehousing and Inventory Management: Metal pallets, especially stackable and rackable designs, allow for optimized warehouse space, efficient inventory organization, and easy movement and retrieval of goods. Their uniform dimensions support Automated Storage and Retrieval Systems (AS/RS).
Transportation and Logistics: Metal pallets provide a stable and secure platform for transporting heavy and bulky goods via various modes of transport, including road, rail, and air. Aluminum pallets are preferred for air transport due to their light weight.
Manufacturing Industry:
Automotive: Widely used for storing and transporting heavy parts such as engines, transmissions, and body panels in production lines and warehouses. Custom designs to accommodate specific parts are common.
Aerospace: Used for handling heavy and large aircraft components, leveraging the high strength and durability of metal.
Electronics: Aluminum and stainless steel pallets are preferred in cleanroom environments due to their non-shedding, anti-static, and non-magnetic properties, used for storing and transporting sensitive electronic components.
Food and Beverage Industry: Stainless steel and aluminum pallets are ideal due to their hygienic nature, ease of cleaning, and resistance to corrosion, ensuring product safety and preventing contamination.
Pharmaceutical Industry: Compatibility with cleanroom environments, resistance to chemicals and bacteria are essential for maintaining product integrity, and metal pallets meet these needs.
Construction and Heavy Equipment Industry: Provide strong support for heavy materials and equipment on construction sites.
Military: Used for transporting ammunition and heavy equipment.
Retail and E-commerce: Facilitate efficient transportation to distribution centers and retail locations.
Chemical Industry: Resistance to leaks, corrosion, and hazardous materials is crucial, and metal pallets offer these features.
Outdoor Storage: Ability to withstand weather conditions without degradation.
Export Industry: Exemption from ISPM 15 regulations (for steel and aluminum pallets) and durability for long-distance transport make them a suitable option.
Comparison of Metal Pallets with Pallets Made from Other Materials:
Metal pallets have specific advantages and disadvantages compared to wooden and plastic pallets:
Comparison with Wooden Pallets:
Advantages of Metal over Wood: Superior strength and lifespan, resistance to pests and moisture, lower likelihood of damage by forklifts, easier maintenance and cleaning, resistance to fire and pests, sustainability, and environmental friendliness.
Disadvantages of Metal over Wood: Higher initial cost, greater weight potentially increasing transportation costs.
Cost Analysis: The initial investment for metal pallets is higher, but the longer lifespan and reduced maintenance costs can lead to long-term cost savings compared to frequent replacement of wooden pallets.
Lifespan Comparison: Metal pallets have a significantly longer lifespan than wooden pallets (10-15 years or more versus a few years or 10-15 uses).
Environmental Impact Assessment: Steel pallets are 100% recyclable, contributing to a circular economy compared to wood and reducing reliance on deforestation.
Comparison with Plastic Pallets:
Advantages of Metal over Plastic: Higher strength and load capacity, better performance in extreme temperatures, fire resistance, often more durable in heavy-duty applications, less likely to slip.
Disadvantages of Metal over Plastic: Greater weight potentially increasing transportation costs, can be noisy, potential for rust (steel) if not properly finished. Plastic pallets can be lighter and resistant to moisture and many chemicals.
Cost Analysis: The initial cost of metal pallets can be higher than some plastic options, but their durability leads to long-term value.
Lifespan Comparison: Metal pallets generally have a longer lifespan than most plastic pallets, especially in heavy-duty applications. High-quality plastic pallets can also have a long lifespan.
Environmental Impact Assessment: Both metal and high-quality plastic pallets are recyclable, offering better sustainability compared to single-use wooden pallets. Plastic production involves fossil fuels, while metal recycling can be energy-intensive.
Table 3: Comparison of Metal, Wood, and Plastic Pallets
Feature | Metal Pallet | Wood Pallet | Plastic Pallet |
| Strength | Very high | Medium | Medium |
| Durability | Very high | Medium | High |
| Initial Cost | High | Low | Medium to high |
| Lifespan | 10-15 years or more | 2-5 years / 10-15 uses | 10 years or more |
| Hygiene | High, easy to clean | Low, prone to moisture and bacteria | High, easy to clean |
| Environmental Impact | Recyclable, reduces deforestation | Renewable, recyclable, biodegradable | Recyclable, production involves fossil fuels |
| Recyclability | 100% | High | Variable |
| Suitable for Heavy-Duty Applications | Yes | No | Depends on type |
| Suitable for Food and Pharmaceutical Industries | Yes (stainless steel, aluminum) | No (hygiene concerns) | Yes (specific grades) |
| Weight | Heavy | Medium | Light |
| Fire Resistance | Yes | No | Depends on type |
Industrial Standards and Regulations for the Design and Manufacture of Metal Pallets:
The design and manufacture of metal pallets are subject to various industrial standards and regulations at the international level:
ISO Standards: The ISO 8611 series specifies test methods and performance requirements for flat pallets, including nominal load testing, maximum working load testing, and durability comparison testing. ISO 445 provides terminology related to material handling, including pallets. ISO 6780 approves six standard pallet sizes for international use.
ASTM Standards: ASTM D1185 covers test methods for pallets and related structures, including static and dynamic tests to estimate stiffness, strength, and durability.
European Standards: UNE-EN 13698-1 specifies construction criteria for 800 by 1200 mm flat wooden pallets. The European Pallet Association (EPAL) regulates the quality and production of Euro pallets. The International Union of Railways (UIC) also has standards related to EUR pallets.
Other Standards and Regulations for International Transport:
ISPM-15: The International Standard for Phytosanitary Measures No. 15 regulates wood packaging (including wooden pallets) in international trade to prevent the spread of pests, requiring heat treatment or fumigation and marking. Metal pallets are exempt from ISPM-15 regulations.
Considerations regarding other regulations related to cargo securement in transport (e.g., FMCSA in the United States).
Market for Metal Pallets:
Global Market Size and Growth Trends: The global logistics steel pallet market was valued at US$ 551 million in 2023 and is projected to reach US$ 707 million by 2030, with a CAGR of 3.6%. Another report estimates the global metal pallet pooling market at US$ 1.2 billion in 2023, forecasting it to reach US$ 2.4 billion by 2032 with a CAGR of 8.5%. The overall global pallet market is much larger, valued at tens of billions of US dollars, with metal pallets forming a smaller but growing segment. Growth in this market is driven by increasing construction and automotive activities, hotel and airport construction, and innovation in the automotive industry.
Major Global Manufacturers of Metal Pallets: Include Morrison Industries, Lockheer, Simon and Dean, Hosken Steel, Mekins, SPS Ideal Solutions, PalletBiz, Al Safrik Steels, Nanjing Huade, and HML GROUP. Other key players mentioned are Steel King, Millwood Inc., Giraffe Storage Solution, Aceally, Metafold, Technosys, and NEFAB Group. Kole Pallet is a leading manufacturer in India.
Analysis of Metal Pallet Price Trends: Prices vary based on material (steel, aluminum, stainless steel), size, and features. New steel pallets can range from US$ 50 to US$ 200 or more. Prices are influenced by raw material costs, production processes, and market demand.
Future Market Forecast for Metal Pallets: The market is expected to continue growing, driven by increasing demand for durable and sustainable materials in logistics, growth in e-commerce, and advancements in manufacturing.
Sustainability and Recycling Aspects of Metal Pallets:
Environmental Benefits of Using Metal Pallets: 100% recyclable, contributes to a circular economy, reduces reliance on deforestation (for steel) and fossil fuels (for plastic), longer lifespan leads to less waste, non-absorbent and easy to clean for hygiene, resistant to fire and pests. Aluminum is particularly known for its high recyclability.
Recyclability of Steel and Aluminum Pallets: Both steel and aluminum are readily recyclable materials, allowing for the recovery and reuse of materials, reducing waste and the need for virgin resources.
Life Cycle Assessment of Metal Pallets Compared to Wood and Plastic Pallets: Life Cycle Assessment (LCA) studies indicate that while metal pallets may have a higher initial energy footprint, their longer lifespan and recyclability can lead to better environmental performance in the long run compared to wood and potentially plastic, depending on the number of uses and recycling rates.
Conclusion and Recommendations:
Metal pallets, as an advanced solution for material handling, offer significant advantages over traditional wooden and plastic pallets. Their unmatched strength and durability, combined with resistance to harsh environmental conditions and complete recyclability, make them a sustainable and cost-effective choice for many industries. The variety in designs and standard dimensions, along with high load-bearing capacity, allows their use in diverse applications from warehousing and transportation to manufacturing and healthcare.
For businesses in Iran considering the use of metal pallets, the following is recommended:
Carefully assess the specific needs of your industry and intended application to select the appropriate type and design of metal pallet (e.g., rackable, nestable, foldable, flat, etc.).
Consider the standard dimensions of metal pallets (North America, Europe, Asia, Australia) based on your region of operation and target export markets to ensure compatibility with equipment and transportation regulations.
Determine the required load-bearing capacity for your products and choose metal pallets with suitable static, dynamic, and racking capacities.
Review the metal pallet manufacturing process and ensure high-quality production methods and appropriate welding and surface finish standards are used.
Compare the types of steel used in pallet construction (carbon steel, stainless steel, aluminum, advanced high-strength steel) and the characteristics of each based on your needs. For the food and pharmaceutical industries, the use of stainless steel or aluminum is recommended due to their hygienic properties and corrosion resistance.
Comply with industrial standards and international regulations related to the design and manufacture of metal pallets (such as ISO 8611 and EPAL standards) to ensure the quality, safety, and global acceptance of your pallets. Also, note that metal pallets are exempt from ISPM-15 regulations for international transport.
Identify major global metal pallet manufacturers and domestic manufacturers in Iran, and review the prices and growth trends in this industry.
Given the increasing importance of sustainability, consider the recycling aspects of metal pallets and the environmental impacts of their use compared to wooden and plastic pallets. Metal pallets are a more sustainable option due to their longer lifespan and recyclability.
By conducting thorough research and considering all technical, economic, and environmental aspects, Iranian businesses can confidently use metal pallets as an efficient and sustainable solution in their supply chain.