Pallets for pharmaceutical and healthcare products
Pharmaceutical plants keep wood out of cleanrooms and GMP areas and use hygienic plastic (closed deck, washable) or aluminum there. Finished goods ship on 48 × 40 in or 1200 × 800 mm wood or plastic pallets to meet distribution, cold-chain and customer rules. The quality system, not a law, sets the material.
- Type
- Plastic (molded)
- Footprint
- 1200 × 800 mm
- Height
- 160 mm
Every dimension is editable. Get the drawing free, or request a quote.
Pharmaceutical supply chains treat the pallet as a contamination risk first and a handling device second. Inside manufacturing, the question is whether the pallet can be cleaned. In distribution, it is whether it keeps product at the right temperature, protects it from damage and can be traced. Regulations such as good manufacturing practice (GMP) and good distribution practice (GDP) set outcomes, not pallet materials; each company's quality system turns those into pallet rules.
Which pallets does pharma use?
| Area | Typical pallet | Why |
|---|---|---|
| Cleanrooms, GMP production, sterile areas | Hygienic plastic (closed deck, no cavities) or aluminum | Washable, low particle shedding, no wood fibers |
| Raw material receiving | Plastic transfer pallets; wood stays outside | Loads are transferred at the boundary |
| Warehouse storage | Rackable plastic or wood | Racking capacity, fire code |
| Finished goods distribution (US) | 48 × 40 in wood block or stringer, pooled, or plastic | Customer and distributor requirements |
| Finished goods distribution (Europe) | 1200 × 800 mm EPAL or plastic | Local standard |
| Cold chain | Plastic or wood with insulated pallet shippers | Temperature control; pallet must fit the shipper |
Why hygienic plastic in production?
A hygienic pallet has a closed, smooth top deck and a closed or smooth base with no hollow cavities, so it can be washed and sanitized and dries without pooling water. Published models from major makers include closed-deck HDPE designs and cleanroom-specific pallets. Aluminum pallets are an alternative where heat, solvents or very long service life matter; they are seal-welded, washable and expensive (a published US price for one 40 × 48 in aluminum model was about $330). See plastic pallets and the plastic pallet buying guide.
| Hygienic pallet feature | Why it matters |
|---|---|
| Closed top deck | Nothing falls through, easy to wipe |
| No open cavities | No hidden water or debris |
| Smooth or welded runners | Cleanable, rides conveyors |
| Virgin resin with a compliance letter | Known material, consistent color |
| Temperature range stated | Ratings change in cold rooms and during hot washes |
| Color coding | Blue or other plant colors for zoning |
Distribution requirements
Once packed, pharmaceutical cases behave like other cased goods, but with added control:
- Temperature. Cold-chain products ship in insulated pallet shippers or refrigerated trucks. The pallet footprint must match the shipper, and plastic avoids moisture problems in reefers.
- Traceability. Pallets carry GS1 SSCC labels and are aggregated to case and unit serial numbers in many programs. See pallet labels and SSCC.
- Security. Tamper-evident stretch wrap or tape, and no mixing of product with other shippers' loads.
- Export. Wood pallets need ISPM 15 treatment; plastic avoids the question entirely.
- Fire code. Plastic pallets in racked storage should be listed to UL 2335 or FM 4996.
Typical loads and weights
Most pharmaceutical loads are light and high value: cased tablets, vials and devices often weigh a few hundred to about 1,500 lb per pallet (estimate). Liquids, IV solutions and bulk active ingredients in drums are heavier. Because the loads are light, pallet choice is driven more by cleanliness, temperature and traceability than by strength, except in high racking.
Common pitfalls
- Wood crossing into controlled areas. Plan a transfer station where loads move from wood to plastic.
- Hygienic pallets that are not rackable. Many closed-deck designs are for floor use or conveyors. Check the racking rating and support condition before putting them in racks.
- Cold ratings. Plastic is more brittle when cold and creeps more when warm. Ask for ratings at your cold-room or washdown temperature.
- Unlisted plastic in the warehouse. Can change sprinkler requirements.
- Pallet footprint vs insulated shipper. Order the pallet to the shipper's internal dimensions.
- Recycled resin. Variable color and composition; pharma specs commonly call for virgin resin.
Spec checklist for a quote
- Use area: cleanroom, GMP production, warehouse, distribution, cold chain
- Material: hygienic plastic (resin, virgin), aluminum, or wood (for distribution only)
- Footprint (1200 × 800 mm, 1200 × 1000 mm or 48 × 40 in) and maximum height
- Deck: closed; base: runners, perimeter or feet; conveyor compatibility
- Load: maximum weight and type; static, dynamic and racking ratings with support condition and temperature
- Washing method and temperature
- Fire listing (UL 2335 or FM 4996)
- Color, branding, RFID or barcode
- Compliance documents: resin letter, certificate of conformity
- Quantity, closed loop or one way
The hygienic plastic 1200 × 800 template is a starting point for a request; plastic pallets are usually chosen from catalog models rather than custom-molded.
Frequently asked questions
Why do pharmaceutical plants avoid wood pallets?
Wood cannot be cleaned or sanitized reliably, sheds fibers and splinters, absorbs moisture and can harbor mold and insects. In controlled environments those are contamination risks, so plants use plastic or metal pallets there and transfer loads at the boundary.
Can pharmaceuticals ship on wood pallets?
Often yes, in distribution outside controlled areas, if the company's quality system and the customer allow it. The pallets should be clean, dry, heat treated if exported, and free of mold.
What is a hygienic pallet?
A plastic pallet with a closed, smooth top deck and a closed or smooth underside with no cavities where dirt or water can collect, designed to be washed. Some models are made for cleanroom use.
Do pharma pallets need a fire rating?
If plastic pallets are stored in a sprinklered warehouse, a UL 2335 or FM 4996 listing usually lets them be treated as wood for sprinkler design. Your fire protection engineer and insurer decide.
Sources and references
Related
- TypesHygienic plastic pallet: closed decks for food and pharmaA hygienic plastic pallet has a closed, smooth top deck and a closed bottom, with no hollow cavities where dirt, water or bacteria can collect. It is made from virgin HDPE or PP, designed to be washed, and used in food processing, meat, dairy, bakery and pharmaceutical plants.
- TypesAluminum pallet: light metal for food, pharma and cleanroomsAn aluminum pallet is a welded metal pallet, usually seal-welded so it can be washed and sanitised. It is lighter than steel, does not rust, is ISPM 15 exempt, and is used in food processing, pharmaceutical cleanrooms and hot or wet processes. It is among the most expensive pallet types.
- TypesPlastic pallets: types, materials, load ratings and how to buy themA plastic pallet is a molded or fabricated pallet made from HDPE or polypropylene. Types range from light nestable pallets (about 14–30 lb) to reinforced rackable pallets (about 35–70 lb). They are washable, ISPM 15 exempt and long-lived, cost several times more than wood, and carry three separate load ratings.
- StandardsUL 2335: fire tests of storage palletsUL 2335, Fire Tests of Storage Pallets, tests how pallets contribute to fire in idle, palletized and rack storage protected by NFPA 13 sprinklers. Plastic pallets listed to UL 2335 or FM 4996 are treated like wood when sizing sprinklers; unlisted plastic raises the commodity class.
- GuidesPallet labels and SSCC-18: the GS1 logistic label explainedAn SSCC (Serial Shipping Container Code) is an 18-digit GS1 number that identifies one logistic unit, such as a pallet, for its whole journey. It is printed as a GS1-128 barcode with Application Identifier (00). GS1 puts pallet barcodes 400 to 800 mm (16 to 32 in) above the base, on two adjacent sides.
- IndustriesPallets for food and beverage manufacturingFood companies run two pallet systems: hygienic plastic or aluminum inside wet and open-product areas, and 48 × 40 in wood or pooled pallets for cased goods. The FDA Sanitary Transportation rule requires suitable, cleanable, sanitary pallets but does not mandate a material.
- GuidesPlastic pallet buying guide: styles, resins, ratings and costChoose a plastic pallet by how it is handled and stored: nestable for cheap one-way use, stackable for floor stacking, rackable for open-beam racking. Compare static, dynamic and racking ratings only when the test standard and support match. New US prices run about $40–200 (2026 estimates).
- TypesHygienic plastic pallet: closed decks for food and pharmaA hygienic plastic pallet has a closed, smooth top deck and a closed bottom, with no hollow cavities where dirt, water or bacteria can collect. It is made from virgin HDPE or PP, designed to be washed, and used in food processing, meat, dairy, bakery and pharmaceutical plants.
More in Industries
- IndustriesPallets for grocery and consumer goodsGrocery runs on the 48 × 40 in pallet: GMA-style stringer pallets or pooled block pallets (CHEP, PECO, iGPS plastic). Retailers set the rules in vendor guides: footprint, entry, condition, height, weight and labels, and some accept pooled pallets only. Check each retailer's current guide.
- IndustriesPallets for the chemical and plastics industryChemical loads (drums, pails, IBCs and 25 kg bags) need heavier, tighter-decked pallets than grocery. Europe uses the CP1 to CP9 block pallets; North America uses 48 × 48 in drum pallets, 42 × 42 and 44 × 44 in sizes and heavy 48 × 40s. Deck gaps and load type matter as much as weight.
- IndustriesPallets for the automotive industryAutomotive supply chains run on returnable plastic pallets, bulk containers and steel racks that cycle between suppliers and plants. OEM packaging guidelines set the footprints; 48 × 45 in is a common automotive size in North America. One-way wood pallets and ISPM 15 crates cover service parts and export.
- IndustriesPallets for beverages: water, soft drinks, beer and spiritsA pallet of bottled water commonly weighs 2,100 to 2,500 lb, and canned drinks and beer 1,500 to 2,200 lb. Most North American beverage loads ship on 48 × 40 in pooled or GMA-style pallets, plus 48 × 20 in half pallets for store delivery. Stiff decks, tier sheets and good wrap prevent crushed loads.
- IndustriesPallets for dairy: milk, cheese, butter and dairy ingredientsDairy uses 40 × 40 in pallets, the size traditionally linked to dairy in North America, and 48 × 40 in pallets for retail DCs. Plants are cold, wet and washed down, so plastic is common inside and wood must arrive dry. Much fluid milk moves in stacked crates on dollies or pallets.
- IndustriesPallets for fresh produceFresh produce ships mainly on 48 × 40 in pallets in North America, many of them pooled block pallets. Pallets must survive wet cooling, cold storage and long reefer hauls and let cold air flow through the load. Imported produce, including from Mexico, needs ISPM 15 treated and marked wood pallets.
Last reviewed 2026-09-24. 796 words.