Plastic vs wood pallets: cost, strength and when to use each
Choose wood when you need the lowest price, a custom size, easy repair or one-way shipping. Choose plastic when pallets run in a closed loop for many trips, when hygiene and washability matter, when you need consistent dimensions for automation, or to avoid ISPM 15 treatment on exports.
- Type
- Plastic (molded)
- Footprint
- 48.00 × 40.00 in
- Height
- 6.00 in
Every dimension is editable. Get the drawing free, or request a quote.
Wood is the default pallet in North America because it is cheap, strong for its price and easy to build to any size. Plastic costs several times more per pallet but can last far longer, washes clean and is dimensionally consistent. The right choice depends on how many trips the pallet makes and how reliably it comes back.
Side-by-side comparison
| Wood pallet | Plastic pallet | |
|---|---|---|
| New price, 48 × 40 in class | about $10–25 (new GMA-style) | about $40–200 depending on style |
| Weight, 48 × 40 in class | about 30–70 lb (14–32 kg) | about 14–70 lb (6–32 kg) |
| Custom sizes | Any size, small runs | Catalog models; custom tooling needs high volume |
| Load ratings | Designed per spec (PDS or testing) | Published static, dynamic and racking ratings |
| Racking | Designed in | Only rackable models, often steel-reinforced |
| Repair | Routine | Not practical; replace and recycle |
| Moisture and hygiene | Absorbs water; can mold | Does not absorb water; washable; closed-deck hygienic models |
| Export (ISPM 15) | Heat treatment and IPPC mark required | Exempt |
| Fire code | Baseline for sprinkler design | Needs UL 2335 or FM 4996 listing to be treated like wood |
| End of life | Repaired, reused, ground to mulch or fuel | Reground into new plastic products |
Prices are 2026 US estimates. Wood prices move with lumber markets; plastic prices move with resin prices, reinforcement and volume.
Cost per trip, not cost per pallet
A plastic pallet costs roughly 3 to 10 times a new wood pallet. It pays back only if you get it back. In a closed loop (for example plant to distribution center and back), the plastic pallet's long life and low damage rate can make its cost per trip lower than wood. In one-way shipping to customers who don't return pallets, wood almost always costs less.
Before switching, estimate: trips per year, loss rate, repair cost for wood, return freight (nestable plastic returns more densely), and cleaning. See pallet cost and reduce pallet costs.
Strength and load ratings
Plastic pallets are sold with three manufacturer ratings: static (on a flat floor), dynamic (on forks or a jack) and racking (spanning rack beams). Racking is the smallest number and the one that limits most buyers. Plastic creeps (slowly deflects) under sustained load, especially when warm, so racking ratings depend on the test standard, beam span and duration. Compare ratings only when you know the standard behind them (ISO 8611 or ASTM D1185).
Wood pallets are designed to the load. A shop sizes stringers or blocks, deckboards and fasteners for your load and support condition, often with the Pallet Design System (PDS) or testing. See pallet load capacity and pallet racking and deflection.
Hygiene, food and pharma
Plastic does not absorb liquids, does not shed splinters or nails, and can be washed and sanitized. Closed-deck hygienic plastic pallets are common in food processing and pharmaceuticals. Food-contact claims should be backed by a letter of compliance for the resin. Wood can be clean and dry, heat treated and kiln dried, but moisture and mold are real risks in humid or refrigerated supply chains. See food-grade pallets and pallet mold.
Export
Solid wood pallets crossing most borders must be treated and marked to ISPM 15. Plastic pallets are outside the standard, which removes treatment, marking and inspection risk. For one-way exports, lightweight nestable plastic export pallets or presswood pallets are common alternatives. See heat-treated pallets.
Fire safety
Building and fire codes base sprinkler protection for idle pallet storage on wood. Plastic pallets listed to UL 2335 or FM 4996 can be treated like wood; unlisted plastic can increase the protection required. Check with your fire protection engineer before storing large quantities of idle plastic pallets. See pallet fire safety.
When to choose each
Choose wood when: shipping one-way; you need a custom size or heavy custom design; price per pallet matters most; pallets will be repaired and reused locally.
Choose plastic when: pallets return in a closed loop; hygiene and washdown are required; automation needs consistent dimensions and no loose nails; exports need to avoid ISPM 15; the environment is wet or outdoors.
To compare plastic styles, see nestable vs rackable. You can open a rackable plastic pallet in the designer to state your requirements.
Frequently asked questions
How long do plastic pallets last compared to wood?
In a controlled closed loop a plastic pallet usually lasts many more trips than a wood pallet, and it does not rot or split. Life depends on handling damage, loads and temperature, so ask suppliers for trip-life data for your application.
Do plastic pallets need heat treatment for export?
No. ISPM 15 applies to solid wood packaging material. Plastic pallets are outside its scope.
Are plastic pallets allowed in warehouses with sprinklers?
Fire codes treat plastic pallets differently from wood unless they are listed to UL 2335 or FM 4996. Unlisted plastic pallets can raise the sprinkler protection required, so check with your fire protection engineer.
Can plastic pallets be repaired?
Generally no. Molded plastic pallets are replaced when damaged and the resin is often recycled. Wood pallets are routinely repaired.
Related
- 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.
- TypesWooden pallets: types, construction, sizes and how to specify themA wooden pallet is a flat transport platform built from lumber deckboards fastened to stringers or blocks. In North America most are 48 × 40 in stringer pallets weighing about 30–70 lb (14–32 kg); in Europe the 1200 × 800 mm EPAL block pallet dominates. Wood must be ISPM 15 treated for most export.
- 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).
- ComparisonsNestable vs rackable plastic pallets: differences and when to use eachChoose a nestable plastic pallet for floor stacking, one-way export and closed loops where cheap return freight matters, since empties nest into each other. Choose a rackable plastic pallet, with runners or a perimeter base and often steel reinforcement, when loaded pallets sit on open rack beams.
- StandardsISPM 15: the wood packaging standard for international shippingISPM 15 is the IPPC standard requiring solid-wood packaging, including pallets and dunnage, to be debarked, treated (HT, DH, MB or SF) and marked before crossing a border. Plywood, OSB, presswood, wood 6 mm thick or less, and plastic, metal and paper pallets are exempt.
- 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.
- GuidesFood-grade pallets: what the term means and how to specify oneThere is no FDA certification for a food-grade pallet. The term means a clean, dry, uncontaminated pallet: new or top-grade wood, kiln-dried and heat-treated (never methyl bromide), or virgin food-contact plastic. FSMA requires transport equipment that will not make food unsafe.
- TypesRackable plastic pallet: runners, reinforcement and racking ratingsA rackable plastic pallet is designed to sit in open-beam racking with nothing underneath. It has runners (3, 5 or 6) or a perimeter or cruciform base, often with steel reinforcement. Racking ratings for 48 × 40 in models are typically about 1,500–4,400 lb, valid only at the tested span and orientation.
More in Materials
- ComparisonsHeat treated vs kiln dried pallets: what the stamps meanHeat treatment (HT) heats the wood core to at least 56 °C for 30 minutes to meet ISPM 15 for export. Kiln drying (KD) lowers moisture content, typically to 19% or less, to reduce mold, shrinkage and weight. Choose HT for international shipping, KD for moisture control, and KD-HT when you need both.
- ComparisonsPresswood vs wood pallets: differences and when to use eachChoose a presswood (molded wood-fiber) pallet for one-way export and air freight: it is ISPM 15-exempt, nails-free, light and nests about 4:1 for storage. Choose a solid wood pallet when you need racking, heavy or custom loads, or pallets you will reuse and repair.
- ComparisonsMetal vs plastic pallets: steel, aluminum and plastic comparedChoose a metal pallet (steel or aluminum) for very heavy, hot, sharp or long-life loads, fire-sensitive storage, or when you need a custom fabricated size in small quantities. Choose plastic for lighter closed-loop handling, lower price, lower tare weight and standard footprints.
- ComparisonsHardwood vs softwood pallets: strength, weight and costChoose hardwood (oak, mixed eastern hardwoods) for heavy loads, rough handling and many trips: it is dense, stiff and holds nails well but is heavier. Choose softwood (southern yellow pine, SPF) for lighter, more uniform, often kiln-dried pallets. Regional supply often decides.
Last reviewed 2026-09-24. 746 words.