With minor adaptations, the racks that hold your pallets can save big dollars in long-term costs, according to John Clarke, research associate of the Pallet and Container Research Lab at Virginia Tech. Clarke spoke recently to the more than 200 attendees at the National Wooden Pallet and Container Association's Pallet Summit held in Indianapolis.

"A wire deck upgrade for $15 one-time can save $2 on every pallet you use or $10-$15 on each plastic pallet you purchase," said Clarke.

These savings are realized by improving pallet support within the racks. This permits the use of less-strong, less-costly pallets that do not have to accommodate wide rack spans. Future pallets can then be designed to fit the new rack structures.

Clarke recommended three ways to achieve the same result: decreasing open rack spans where possible, adding cross bars across the spans, and installing wire decking. These are all feasible changes that promote safety in addition to allowing users to save on pallet purchases.

Clarke suggested that facilities installing new racks also consider the long-term benefits of using less expensive pallets.

"The cost of adding this equipment one time can greatly reduce future shipping costs," he added, as less-dense pallets are cheaper to ship.

Proper conveyor selection can also save money on pallets. Skate conveyors, for instance, can be built with middle supports to better handle more economical pallets. Similarly, a middle chain can be added to chain conveyors to move pallets more easily.

Clarke additionally compared strength, durability, and the effects of particular facility environments on a variety of pallet materials, including wood, plastic, corrugated, and metal. He noted that additional savings can be realized by selecting the correct pallet style and material to perform the required task.