Pallets that make the extra trip
There's more than one way to keep pallets in circulation.
By Megan McCoy, Assistant Editor -- Modern Materials Handling, 3/1/2003
Without question, pallets are the unsung heroes of managing inventory in warehouses and distribution centers. Just try to efficiently unitize a load of substantial size and weight without the help of a pallet. Yet, they are clearly taken for granted. Until, that is, something goes wrong - deckboards are damaged, nails exposed, or the pallet becomes unusable in some other way.
Whether pallets are made of wood, plastic or metal, warehouse managers are most interested in durable pallets. It doesn't matter whether they are used once or multiple times. But there is clearly a trend to reducing pallet costs by getting as many trips as possible from a pallet.
According to a survey of readers last year, 70 percent of them get more than one use from a pallet. Yet, most are not taking advantage of pallet repair, recovery and leasing programs that can maximize the number of trips while reducing costs. It doesn't have to be that way, however. There are several options available from in-house programs to outsourcing of these activities. Regardless of the path you choose, it's all about getting the biggest bang for the buck.
Pallet options
Of all types of pallets, wood ones are the old standby. In fact, wood is still the most commonly used material for pallet construction - by a wide margin. Nearly 400 million wood pallets are produced annually, accounting for 86 percent of all pallets sold, according to that same survey. Plastic comes in second, accounting for almost 9 percent of pallets sold, with wood composite at 2.1 percent, corrugated cardboard at 1.7 percent and metal at 1.5 percent.
While many warehouse managers care only that a wood pallet survives an initial trip, there are others, especially those using them in closed-loop systems and for internal slave purposes, that require longer life. Quality and durability matter greatly in these applications. Two-thirds of wood pallets are made from hardwoods with the balance from softwoods. The former is typically more durable and long lasting than the latter.
Other types of materials for pallets include plastic and metal. Manufactured by two methods - injection molding for lighter weight loads and structural foam molding for heavy-duty applications - plastic pallets are reusable for hundreds of roundtrips and provide product protection since they have smooth surfaces with no nails. Many plastic pallets often are lighter weight than wood pallets and offer space savings because they are nestable.
Metal pallets are most suitable for long-term, extensive use and offer many of the same benefits as plastic pallets. These heavy-duty pallets are recyclable, easily repaired, and capable of handling loads as heavy as 24,000 pounds or more.
Managing multiple uses
As pallets are used time and again, a proper maintenance and repair operation needs to be in place if you plan to continue use after damage. Options here include: in-house programs as well as outsourced repair, closed-loop and leasing programs.
Some companies such as Revlon have aggressive in-house maintenance and repair operations. At its former Phoenix distribution center, the company sorted and repaired pallets each day in its pallet yard. Two full-time people manned the yard.
In addition to maintaining pallet quality for use in an automated storage and retrieval system, the men received, sorted and upgraded used pallets. Costs for the used pallets were extremely low, more than covering labor costs for repairing them. Pallets that came from manufacturing were also handled by the pallet repair program, ensuring top quality throughout all operations. At its peak, the yard maintained and repaired 63,000 pallets a year at an average cost of $1.50 apiece.
On the outsourcing side are offerings by pallet recycling and reconditioning programs, some of which are offered by pallet manufacturers. These programs pick up and sort used pallets and then repair them to suitable standards and specifications before returning the pallets to the warehouse. Even heavily damaged pallets can be reused since the worn-out pallets are disassembled and some of its components used to repair other pallets.
One example here is a company called Pallet Management Systems. This Web-based supply chain management system tracks, sorts, repairs, warehouses, and returns pallets to your DC. All pallets are owned by Pallet Management Systems. The company guarantees that its customers will save from 15 to 50 percent.
Orbis Corporation, a manufacturer of plastic pallets and packaging materials, also operates recycling centers. Instead of disposing of damaged plastic pallets, customers can ship their clean but unusable pallets to the nearest Orbis recycling center to receive a credit towards their next purchase of Orbis products. Pallets received by Orbis are recycled into other useful products.
Yet another alternative is pallet leasing companies such as Chep. Although the pallets are part of your supply chain, they are owned and maintained by Chep.
The operation of the program is simple. The leasing company supplies warehouses with the ready-to-use requested pallets. The warehouse staff then loads their products onto the pallets and ships them to the in-tended receiver. Once a warehouse receives and unloads the products, it returns the pallets to the nearest service center of the leasing company. The pallets are inspected and prepared for the next use and the cycle begins again.
Such a program allows pallet users to utilize a specific pallet without the high costs of purchasing customized pallets in bulk quantities. Also, whether the leased pallets are customized or standard, the pallet users can leave the trouble and expense of repairing or disposing of pallets to the leasing program.
Pallets and the methods of obtaining them are as varied as the products that they ship. Own a full stock of metal or plastic pallets; outsource pallet requirements to a leasing company; or repair pallets for continued use. By any means, long live the pallet!
Pallet is flame retardant
The Universal Pallet with Flame Edge technology is a flame-retardant plastic pallet with a capacity of 2,800 pounds and good impact resistance. Features include anti-slip rubber plugs on the deck, rails and feet to stabilize loads, easy-to-clean surfaces, four-way entry and beveled fork openings for easy alignment with fork tines.
Buckhorn
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Metal pallets
A full line of metal pallets is available in light-, medium- and heavy-weight capacities. Size dimensions for the three types are 40 x 36 inches and 40 x 40 inches (light), 42 x 42 inches and 48 x 48 inches (medium), and 48 x 60 inches and 48 x 72 inches (heavy). Designed as an alternative to wood and plastic pallets, the metal pallets are compact, environmentally friendly, splinter-proof and easy to decontaminate. Available coatings include raw steel, galvanized and painted.
International Metal Pallet Co.
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It's a double decker
Stackable plastic pallets feature an inverted cone design to provide strength and easy snap together assembly. Weighing only 29 pounds, the lightweight pallet is constructed of a recyclable polypropylene blend and features an anti-skid surface molded on the deck and bottom. The pallet measures 48 x 40 x 5.5 inches and is available with steel support struts.
American Pallet and Manufacturing Co.
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Buy and sell pallets online
A Web site allows pallet buyers to quickly locate their pallet needs and lets pallet suppliers easily list pallets for sale. Pallet buyers can enter the number and characteristics of the desired pallets and then read a description and request a quote. Suppliers can enter up to ten listings of pallets for sale.
gotpallets.com / A Service of Ongweoweh Corp.
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A pool of pallets
A pallet leasing service provides a closed-loop pooling system by issuing ready-for-use pallets and containers to manufacturers and receiving the pallets from the end-user. With over 200 million reusable pallets and containers in stock at service centers located in 38 countries, the company can also assume responsibility for repairing and recycling the pallets.
CHEP
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Plastic pallet with two-piece design
Ideal for export applications, a 40 x 48 inch stackable pallet features a two-piece design to optimize storage space. The pallet is structurally molded of high-density polyethylene for high strength-to-weight ratio and superior static load capacity. Features include four-way forklift and handtruck entry, a 3,500 pound dynamic load capacity and an optional textured deck to prevent products from shifting during transport.
Orbis
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