Comprehensive Collection of Research Regarding the Sustainability of Wooden Pallets

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Wooden pallets are one of the most sustainable forms of packaging available in the market. This claim is backed by numerous research papers and studies ranging from ones published by reputable industry associations to prestigious universities. The reason for the green nature of the wooden pallet is the product’s rate of recycling, durability, and multiple end-of-life recycling streams. For example, a wooden pallet can be used many times before requiring any type of repair. Once a repair is needed, a small companion stringer (link to companion stringer blog post) or staples can be enough to return the pallet to “like-new” durability and performance . Once a pallet has been repaired multiple times, and is no longer in the capacity to be restored to usable condition, it can still serve a valuable purpose as the source material for wooden fuel pellets, mulch, animal bedding, and other sustainable byproducts.

Below is a collection of research and studies that highlight the sustainable nature of the wooden pallet. We have organized our collection by the date the research was published. This collection will be regularly updated and maintained.

Report: The Life-Cycle Analysis of Wooden Packaging

Source: The Polytechnic University of Valencia, Spanish Federation of Wooden Packaging and Components (FEDEMCO)

Year Released: 2023

Summary: The findings of this report concluded that wood is the most sustainable packaging option for fruit and vegetables. The report states that wood has a lower environmental impact across all areas, especially in terms of greenhouse gas emissions, pollution, ecotoxicity, and food safety.

Link to report highlights on Eurofruit: https://www.fruitnet.com/eurofruit/new-study-endorses-wood-as-the-most-sustainable-packaging-for-fandv/256847.article

Link to direct press release from FEDEMCO (Spanish): https://fedemco.com/2023/10/31/el-envase-de-madera-avalado-como-el-mas-sostenible/

Research: Environmental Product Declaration (EPD) for Wood Pallets manufactured in the U.S.

Source: National Wooden Pallet and Container Association (NWPCA), The Pallet Foundation, U.S. Forest Product Lab.

Year Released: 2020

Summary: The UL certified EPD released in 2020 features a full life-cycle assessment of a wooden pallet. A life-cycle assessment showcases the environmental impact of a product through each stage of its life-cycle – cradle to grave.

The findings of the EPD conclude that with proper disposal and recycling practices wooden pallets can be considered a carbon-neutral product.  It also proves that repairing (reconditioning) a pallet or using harvested wood materials from tear-down pallets (remanufacturing) to build pallets is far more environmentally friendly than manufacturing a brand-new pallet.

The EPD can serve as a useful tool in comparing your own pallet operations to the industry benchmarks, along with using the research as the source for your own environmental impact calculations.

Link to NWPCA statement and resources surrounding EPD: https://www.palletcentral.com/page/epd

Direct link to full EPD: https://cdn.ymaws.com/www.palletcentral.com/resource/resmgr/industry_resources/EPD-report-wood-pallets.pdf

Direct link to Life-Cycle Assessment Report: http://palletcentral.uberflip.com/i/1310254-life-cycle-assessment-of-wooden-pallet-production

Study: Life-cycle assessment comparison of wooden and plastic pallets in the grocery industry

Source: The Pennsylvania State University

Year Released: 2020

Summary: In the Penn State study, researchers compared the long-term performance of treated wooden and plastic pallets through a detailed, cradle-to-grave life-cycle assessment, and conducted an analysis of treatments required to kill pests such as insects. They investigated and evaluated the environmental impacts of resources consumed and emissions released by wooden and plastic pallets throughout their life cycles.

The conclusion of the study was that wooden pallets are slightly more environmentally friendly and sustainable than those made of plastic.

Link to press release announcing the findings: https://www.psu.edu/news/research/story/wooden-or-plastic-pallets-which-are-more-eco-friendly/

Direct link to study: https://pure.psu.edu/en/publications/life-cycle-assessment-comparison-of-wooden-and-plastic-pallets-in

Research: Disposal and Recovery of Wood and Wood Packaging in the United States

Source: Virginia Tech

Year Released: 2018

Summary: This study was independently conducted at Virginia Tech over the course of two years and concluded that 95% of wooden pallets in the United States are recycled. Both municipal and solid waste (MSW) and construction and demolition (C&D) landfill facilities were surveyed to better understand how pallets were being handled at these facilities.

Link to press release announcing the findings: https://www.palletcentral.com/news/393334/Study-Shows-95-of-Wooden-Pallets-are-Recycled.htm

Direct link to research supporting the findings: https://vtechworks.lib.vt.edu/bitstream/handle/10919/84346/Shiner_ZP_T_2018.pdf?sequence=1&isAllowed=y

Model: EPA Waste Reduction Model (Warm)

Source: United States Environmental Protection Agency

Year Released: 1998, latest update (Version 15) released in September 2022.

Summary: EPA created the Waste Reduction Model (WARM) to provide high-level estimates of potential greenhouse gas (GHG) emissions reductions, energy savings and economic impacts from several different waste management practices.

GHG savings are calculated by comparing the emissions associated with managing materials under an alternative scenario with the emissions associated with the user’s baseline scenario (i.e., current practices), as opposed to simply multiplying the quantity of materials managed by an emission factor.

While pallets are not a material listed in the WARM model, a close substitute is – dimensional lumber. For many years the pallet industry has been using the WARM model (based on dimensional lumber) to calculate carbon emission savings from pallet recycling. While there is more specific research available to the pallet industry since the release of the EPD in 2020, pallet recyclers are still using the WARM model due to how easy it is to apply to pallet recycling operations and get a number. However, just because the number produced does not mean it is accurate and definitive. Because the model is based on dimensional lumber and not pallets specifically, it is not 100% accurate.

What is a Notched Pallet Stringer?

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A notched pallet stringer is a type of wooden beam used in the manufacturing of new and recycled pallets that allows for four-way entry on a wooden pallet. Unlike standard stringers with smooth surfaces, notched stringers feature indentations or “notches” along their length. These notches create openings in the pallet deck, allowing for easier forklift access from all four sides.

A side by side PDS drawing of a notched pallet stringer and an un-notched pallet stringer.

A Brief History of Notched Pallet Stringers

The first wooden pallet was patented in 1924, but significant advancements in pallet design didn’t occur until the mid-20th century, when pallets began incorporating wooden runners (stringers). Click here to read the full 1924 pallet patent. A major breakthrough came in 1977 with Thomas O. Mills’ invention: a machine specifically designed to create notches in stringers. Click here to read about Mills’ invention. Before this machine, creating notched stringers was a laborious task, often done by hand – a time-consuming and potentially inaccurate process. Thanks to this innovation, notched pallet stringers have become the industry standard, offering numerous advantages over their un-notched counterparts.

How a Notched Pallet Stringer is Made

  1. Harvesting & Processing: Sustainable forestry practices yield the lumber used to create pallet stringers. After debarking and trimming, logs are cut into cants. These cants are then further processed, with each stringer typically utilizing approximately 4.85 board feet.
  2. Notching & Waste Minimization: Stringers are precisely notched using specialized machinery. Waste material generated during the notching process is repurposed as mulch or fuel pellets, minimizing environmental impact.
  3. Pallet Integration: Notched pallet stringers are integral components of 4-way pallets. When necessary, companion stringers, often crafted from salvaged material, are used to reinforce existing stringers and extend pallet lifespan.
  4. End-of-Life Management: At the end of a pallet’s service life, it is dismantled. Salvageable components are recovered, while remaining materials are repurposed as mulch, animal bedding, or fuel pellets.

Key Notched Pallet Stringer Benefits

  • Four-Way Entry: The most significant advantage of notched stringers is their ability to facilitate forklift entry from all four sides of the pallet. This four-way entry significantly enhances handling efficiency and reduces the risk of damage to goods during loading and unloading. Click here to read about the key differences between 4-way and 2-way entry.
  • Increased Versatility: The open design of notched stringers makes them highly versatile. They are great for pallet handling and can be stacked in various configurations, accommodating different warehouse layouts and operational requirements.
  • Improved Stability: While primarily known for their handling advantages, notched stringers can also contribute to improved pallet stability in certain applications. The notches can provide a degree of flexibility in the pallet structure, allowing it to adapt slightly to uneven surfaces.
A close-up look at a single notch on a notched pallet stringer.
Close-up look at a notched stringer on a wooden pallet

Industries that utilize notched stringers

  • Manufacturing: Ideal for handling diverse products and accommodating various production and shipping processes.
  • Warehousing & Distribution: Their four-way entry and versatility make them highly efficient for storage and transportation operations.
  • Retail: Widely used to transport and display goods in retail settings, offering easy access for stock replenishment and customer pickups.
  • Food & Beverage: Suitable for handling a wide range of food and beverage products, ensuring safe and efficient transportation.
  • Construction: Used to transport building materials, offering flexibility and ease of handling on construction sites.
  • Other: This list is not exhaustive. Many other industries, including agriculture, pharmaceuticals, and even the automotive industry, utilize notched stringer pallets to improve their material handling processes.

By understanding the unique benefits of notched stringer pallets, businesses can optimize their material handling operations, improve efficiency, and minimize the risk of damage to their goods.

Our pallets comply with Australian and international standards

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Plain Pallets is proud to announce that we have been listed on the Australian Trade and Investment Commission website as a pallet supplier.

Austrade is committed to helping Australia’s economic prosperity by providing businesses and other institutions with best market information and insights.

Austrade provides:

  • Help for Australian export businesses that wish to grow in international markets.
  • Government assistance to promote and facilitate foreign investment.
  • Advice to the Australian government on its trade, tourism and other international policies.

What this means for Plain Pallets

austrade listed pallet supplierPlain Pallets is now an Austrade listed supplier.

We’re pleased that our hard work and dedication has been recognised with our Austrade listing. Here at Plain Pallets, we are dedicated to provided our customers with the best possible products and service.

With over 40 years of experience, we are industry leaders in pallets for both domestic and export purposes.

We have a range of export pallets which match the standard dimensions of different export destinations as well as the ISPM 15 regulations for treated timber pallets.

Alongside Austrade, we are proud to facilitate the growth of Australian export industries with our ISPM 15 compliant export pallets.

export wooden palletsPlain Pallets can supply pallets that meet Australian and international standards.

What this means for you

With Plain Pallets, you can be sure that you’re getting high-quality pallets which comply with Australian and international regulatory standards.

ISPM 15 regulations require that all wooden export pallets are treated to destroy potential threats to local flora and fauna, including fungi and pests.

Our export pallets, both wooden and plastic, will not hold up your goods as they pass through customs.

Our domestic pallets are also manufactured to the highest quality standards and covered by our full public liability insurance.

As one of the longest running pallet suppliers in Melbourne, you can trust our experience and expertise.

Plastic or Wood Pallets: Which Material Should You Choose?

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It can seem hard to get excited about pallets. After all, how interesting can a pile of wood or plastic be?

However, pallets play such a large role in shipping that they can be said to “move the world”. Slate even named pallets the single most important object in the global economy.

So businesses must weigh up the economic decision as to whether plastic or wood pallets are better suited to their needs. But in the midst of the green revolution, are environmental factors also affecting that decision? Are economics and environmental friendliness diametrically opposed? Or are they more akin than most would think?

Plastic Pallets

plastic palletsPlastic pallets are typically used for fresh food, freezer conditions and pharmaceutical and hygienic requirements. Plastic pallets offer a hygienic environment for products that require high levels of cleanliness, as they can be hot washed or chemically sterilized. While wood can be cleaned, it can’t meet the same hygienic standards as plastic as it is porous and can retain moisture and bacteria.

But while plastic pallets are often advertised as eco-friendly, when damaged they cannot be repaired in the same way that wood pallets can. As plastic pallets are made from oil, they must be melted down to be recycled. However, they have a longer shelf life than wood.

Another benefit of plastic pallets is that they can serve a dual purpose. Manufacturers can pack products into a plastic pallet and the retailer can then use it as a store display. Plastic pallets are also ideal for use on pallet wrapping machines with their increased durability.

The main benefit of plastic pallets is being able to re-use them – but it’s important to remember that plastic pallets cost three times the price of wood.

Wood Pallets

wood palletsWood pallets are less expensive than plastic pallets and widely used for a number of products. They also hold more weight than plastic, as they can hold between 1,500 and 3,000 pounds. For heavy items, wood pallets are your best choice.

They’re also recyclable. Unlike plastic, wood pallets are made of a sustainable resource (scrap wood) which would otherwise be wasted. Whereas plastic pallets are stiff and difficult to repair, wooden pallets are easily repaired and can be reused. Due to the lower cost, typically wooden pallets don’t have to be reused and are used to export good overseas.

However, wood pallets are not typically good for fragile items because of the fasteners on wood pallets. They pose a puncture hazard and could result in damaged goods, delayed arrivals, and unhappy customers.

Wood pallets can also give off moisture and harbor bugs. Depending on the products being shipped, this may not be a problem. As previously mentioned, products that require a high level of hygiene are better suited to plastic pallets.

Wood pallets do not have the same fire safety rating as plastic. Plastic pallets burn at a much higher temperature than wood, and so building fire codes play a role in the purchasing decision for many manufacturers.