Custom Pallet Manufacturing
Standard pallets do not fit every product. When your load dimensions, weight requirements, or industry regulations call for something unique, GreenCycle Pallets engineers and manufactures custom wood pallets right here in Sunnyvale, California. From concept sketches to full production runs, our in-house design team and automated manufacturing line deliver precision-built pallets that protect your products and optimize your logistics.
Start Your Custom Project
Share your dimensions, load requirements, and volume. We will respond with a design proposal within 48 hours.
Any Size, Any Configuration
We build pallets from as small as 24 × 24 inches up to oversized platforms exceeding 72 × 72 inches. Two-way or four-way entry, flush or overhang deck, notched or full stringers—every variable is adjustable to your needs.
Stringer Pallets
The most common design, using two or three parallel stringers. Ideal for general warehousing and compatible with most forklift types. Available in two-way and partial four-way entry.
Block Pallets
Four-way entry design using blocks between deck boards and bottom boards. Superior accessibility for pallet jacks and automated systems. Preferred for high-throughput distribution centers.
Skids & Platforms
Single-deck platforms without bottom boards, used for heavy machinery, export crating, and one-way shipments. We build skids to any dimension with reinforced construction for extreme loads.
Materials Available
Southern Yellow Pine (SYP)
The workhorse of the pallet industry. Excellent strength-to-weight ratio, readily available, and cost-effective. Ideal for general-purpose pallets and export applications.
Oak & Hardwood
Maximum load capacity and durability. Hardwood pallets withstand heavier payloads and harsher handling, making them the choice for automotive, steel, and heavy industrial applications.
SPF (Spruce-Pine-Fir)
Lightweight softwood blend from Bay Area mills. Lower cost and lighter weight reduce shipping expenses—perfect for air freight and single-use export pallets.
Recycled & Reclaimed Lumber
Sourced from our own recycling operation. An eco-friendly option that uses de-nailed, re-milled boards from end-of-life pallets. Same structural performance at a lower environmental cost.
Design Consultation & Prototyping
Not sure exactly what you need? Our design team starts with your product dimensions, weight, and handling requirements and works backward to the optimal pallet configuration. We use PDS (Pallet Design System) software to model load distribution and stress points, ensuring every pallet performs safely under real conditions.
Before committing to a full production run, we build a small batch of prototypes for you to test in your actual environment—on your racks, through your conveyors, and in your trucks. Adjustments are made until the design is exactly right. Prototyping typically takes 3–5 business days, and the cost is credited toward your first production order.
Production Capacity
Our Sunnyvale manufacturing facility operates two shifts and is equipped with automated nailing machines, precision cut-off saws, and a dedicated heat-treatment kiln. Current capacity handles up to 2,500 custom pallets per day, with the ability to scale for surge orders. Lead times are typically 5–7 business days for standard custom orders and 10–14 days for complex or oversized builds.
Industries We Serve
Aerospace & Defense
Precision-milled pallets with tight dimensional tolerances for sensitive equipment and components that demand careful handling and secure shipping.
Food & Beverage
Clean, heat-treated pallets built to FDA and FSMA guidelines. Smooth surfaces prevent product contamination, and ISPM-15 compliance enables international export.
Pharmaceuticals
Contamination-free pallets manufactured in controlled conditions, with full batch traceability and documentation to support GMP compliance.
Automotive
Heavy-duty pallets engineered for engine blocks, transmissions, and other high-weight components. Reinforced stringers and hardwood construction for maximum load capacity.
Electronics & Tech
Lightweight pallets with anti-static treatments and cushioned deck options to protect sensitive electronic assemblies during transit and warehousing.
Agriculture & Nursery
Weather-resistant pallets sized for greenhouse flats, bagged goods, and produce crates. Available in treated softwood to resist moisture and biological decay.
FAQ
Frequently Asked Questions
What details do you need to design a custom pallet?
We need load weight, dimensions, handling method, material preference, and any automation or rack requirements.
Is there a minimum order for custom pallets?
Typical minimum is 50 units; prototype runs can be smaller for fit and line testing.
Can you build to tight tolerances for conveyors and ASRS?
Yes—on request we hold ±1/8 inch tolerances and verify dimensions before shipment.
Do you offer heat-treated or plastic custom pallets?
We build in wood, hybrid, or plastic and can heat-treat wood designs for ISPM-15 compliance.
How long does production take after I approve drawings?
Standard lead time is 7–14 days; rush production is available for repeatable designs.
Your Product Deserves a Perfect Pallet
Let GreenCycle Pallets engineer a custom solution that fits your product, your process, and your budget.
All ServicesStart a Custom Order