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Custom-designed extra long pallets

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A leading custom pallet, crate and skid manufacturer in Sydney has released two new products twice the size of a standard pallet designed for carrying unusually long and heavy products. 
Pace Pallet Services design team said they faced unique challenges in creating the large pallet systems for their customers.
“Our first challenge was to design an oversized pallet to carry stacks of cartons nearly twice the size of a standard pallet,” managing director Michael Mourad said.
“Our customer manufactures DIY garden sheds which are flat packed so that they be sold via a national retail chain. The cartons measure 2040mm by 950mm which is nearly twice as long a standard pallet.”
Mourad said the design team used specialised software to develop a pine timber pallet with the dimensions of the cartons.
“We realised early on that a forklift or pallet jack would have to approach the pallet from the long side which is unusual,” Mourad explained.
“We put an extension tine on our forklift and put the pallet through its paces with heavy loads on flat pack sheds: it worked well.”
Mourad said the client than tested the pallet’s strength and integrity with their own OH&S team.
“The Pace Pallet Services design passed with flying colours and an order was placed for 280 pallets.”
The next design was for Australian Metal, a steel manufacturer that required a pallet which would carry loads of steel products used for rail carriages and weighing up to two tonnes. The loads would also need to be 6 metres to 11 metres in length.
“The job for Australian Steel was quite unique because the longest length of pine timber is 6 metres,” Mourad explained.
“For anything larger than that we had to think outside the square and join timbers to make up the length whilst not compensating the overall strength of the pallet.”
Mourad said pine timber was chosen over hardwood due to its cost effectiveness, but that this mean the company had to design the pallets in such a way that they offered durability from a ‘soft’ product.
“The final custom-designed solution is a demonstration of the company’s understanding of the engineering strengths of timber materials,” Mourad said.

“The steel products were then shipped from the Eastern Seaboard to Western Australia, meaning the extra-long pallets had to survive a long journey.”

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