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Product Base Dimensions
The first technical input in custom-size pallet design is the actual base footprint through which the product contacts the pallet. Although the maximum external width and length of the product help define the overall pallet boundaries, the load-bearing system is not designed solely according to these values. Machine feet, chassis members, wheels, mounting plates, and transport skids may transfer the product load to the pallet at different points. A wide upper body may stand on a narrow chassis, or protective projections may extend beyond the product’s main external dimensions. For this reason, the maximum product envelope and the base geometry in direct contact with the pallet must be measured separately and shown on the technical drawing.
When measuring the base dimensions, the product must be shipment-ready and positioned exactly as it will be transported on the pallet. If equipment that normally stands upright will be transported horizontally due to logistics constraints, the pallet dimensions must be calculated according to the new contact surface. Width, length, and contact points should be recorded in millimeters, and the reference edges used for measurement should be specified. Projecting components such as motors, pipes, control levers, or fixed accessories must be included when determining the maximum pallet boundary. Measurements should not be taken before movable components have been locked in their shipment positions.
The outside-to-outside distance between machine feet, the width of each foot, and the location of connection holes form the basis of custom pallet design. If the product stands on four feet, not only their general arrangement but also, where possible, the proportion of load carried by each foot should be provided. A foot located beneath a heavy motor section may transfer more force than the others. Cross members and main load-bearing components must be positioned beneath these points. If bolted securing will be used, hole centers must align with structural members rather than being applied only to thin top boards.
For wheeled products, the base dimensions are evaluated using the outside-to-outside wheel spacing and the ground contact area of each wheel. The presence of wheel brakes alone is not sufficient to secure the product during transport. Shaped stops that limit forward and backward movement, along with side supports where necessary, should be used. Wheels must not align with gaps between pallet boards, and point loads must be supported by structural cross members. Because small-diameter wheels can apply high pressure to a narrow area, the top surface may require additional reinforcement.
For cylindrical, round, or irregular products, a conventional rectangular base measurement may not be sufficient. Rolls, reels, tanks, pipes, and similar loads require cradle or chock systems matched to the product diameter. The outer boundaries of these supports are included in the pallet’s total width and length. The chock angle must prevent rolling without applying excessive pressure to a small surface area. When multiple cylindrical products are transported on one pallet, separator and securing spaces between the products must also be calculated. The pallet base should be enlarged according to the support geometry, not merely the combined width of the products.
The clearance left between the product and the pallet edge must be determined according to transport and securing requirements. Product overhang may create contact with surrounding loads and increase the risk of packaging damage. However, making the pallet unnecessarily large can reduce vehicle and warehouse space efficiency. If straps, bolts, chocks, corner protectors, or external packaging will be used, the space occupied by these components must be added to the base dimensions. Forklift channels and load-bearing beams must be arranged so they do not interfere with the product. Safe clearances should be calculated individually according to the securing system rather than by adding the same arbitrary value in every direction.
When multiple products are transported on the same custom-size pallet, the base area of each item and the safe clearance between them must be evaluated together. Heavy items should not be grouped on one side of the pallet, and the combined center of gravity must remain within the supporting area. Products can be separated with partitions or chocks to prevent contact. Small accessories should be secured inside closed boxes instead of being left loose on the pallet. Loading and unloading sequence may also affect the layout. Ensuring that the first item to be removed is accessible without dismantling the others can reduce operational time.
Data Required for Base Dimensions
Maximum product width and length, foot spacing, contact surfaces, connection holes, transport orientation, projecting parts, and securing clearance should be shown on the same technical drawing.
When requesting a quotation for a custom-size pallet, current technical drawings showing top and bottom views, photographs from different angles, and verified physical measurements should be provided. It should be clearly stated whether each value represents the product’s external dimensions or the base contact dimensions. In the pallet plan prepared by the manufacturer, the product envelope, foot positions, main load-bearing components, cross members, and forklift entries must be reviewed separately. Evaluating the product base dimensions together with the actual load points prevents unnecessary pallet enlargement while supporting load capacity, securing safety, and compatibility with logistics equipment.
Load Distribution and Carrying Capacity
In custom-size pallet design, carrying capacity cannot be determined solely from the product’s total weight in kilograms. Two products with the same weight may create different force distributions on the pallet because they contact the base differently. A load with a wide contact surface transfers weight more evenly, while a machine standing on four narrow feet can create high point loads in small areas. The pallet’s main skids, cross members, and upper surface must be designed according to these load paths. Without information about foot locations, contact areas, and the position of heavy components, total weight alone is insufficient to determine the actual structural requirements.
To understand load distribution, the product’s bottom view and approximate center of gravity should be shown on the technical drawing. A motor, gearbox, cast body, or dense metal section may make one side of the product heavier than the other. A geometrically symmetrical load may therefore behave asymmetrically on the pallet. Structural sections beneath the heavy area can be reinforced, and the forklift entry direction can be determined accordingly. If the product manufacturer can provide individual foot loads, these values should be used in pallet design. When exact data is unavailable, an estimated upper limit should be stated and verified before production.
The pallet’s operating conditions must be clearly defined when assessing carrying capacity. A pallet resting on a flat floor, one lifted on forklift tines, and one supported by only two warehouse rack beams behave differently under the same load. On the floor, a large portion of the base may be supported, while rack storage increases the unsupported span and creates bending in the beams. During forklift lifting, the load is carried through limited tine contact areas. Therefore, one capacity value should not automatically be considered valid for every operating condition. Dynamic transport, static storage, and rack use must be evaluated as separate scenarios.
Main skids are the primary components that transfer the pallet load to forklift tines, rack beams, or the vehicle floor. Their section, quantity, and spacing are determined according to pallet length and product weight. In long custom pallets, increasing spans may increase the risk of bending in the center. Additional skids or intermediate supports can help distribute the load over a wider area. Positioning skids only at the pallet edges may be inadequate when product feet are concentrated near the center. Structural members must be planned together with the product contact points and forklift channels.
Cross members and upper load-bearing components distribute forces from the product feet to the main skids. If the cross members do not align with the actual foot positions, the load may be transferred to thin top boards or connection areas. Where bolted securing is used, the connections must pass through structural cross members. When the product does not sit directly on the pallet, chocks and intermediate blocks also become part of the load distribution system. Attaching chocks only to surface boards may be insufficient for heavy loads. The force path should remain continuous from the chock through the cross member and into the main skid.
Fasteners affect the continuity of carrying capacity. Nails, screws, bolts, metal plates, and straps must be selected to hold pallet components together under load. Large timber sections joined with inadequate or incorrectly positioned fasteners may not provide the expected strength. In reusable custom pallets, connection areas should be checked for loosening and wear during every cycle. Repeated use of the same bolt hole may enlarge the opening in the timber. Replaceable connection plates or maintainable components can support a longer service life.
Strap and bolt forces applied while securing the product also add loads to the pallet structure. Over-tightened straps may crush the packaging or pull pallet boards upward. Insufficient tension may allow the product to move. Bolted connections pull the product chassis toward the pallet and must distribute force evenly through the structural members. A heavy product should not be assumed to remain in position through friction alone. The securing arrangement should be designed according to the product geometry to limit forward, backward, lateral, and, where necessary, upward movement.
Factors Determining Carrying Capacity
Total weight, point loads, center of gravity, structural sections, support spans, fasteners, forklift lifting, and rack usage conditions must be evaluated together.
When requesting a custom-size pallet quotation, the product’s net weight, possible maximum weight, individual foot loads, contact areas, center of gravity, and operating conditions should be provided. It should be clearly stated whether the pallet will be used on a flat floor, inside a vehicle, on a forklift, or in a racking system. The manufacturer’s plan should be checked for skid sections, cross-member positions, support spans, bolt locations, and permitted lifting directions. Calculating load distribution according to the actual combined scenario created by the product and logistics equipment prevents unnecessary pallet weight while ensuring that safe carrying capacity is created in the correct areas.
Chock and Skid Structure
The chock and skid structure consists of the main components designed together to carry the product weight, restrict load movement, and provide compatibility with forklift operations. Skids extend along the lower section of the pallet in the transport direction and transfer the load to forklift tines, vehicle floors, or warehouse surfaces. Chocks support the product at specific points and prevent rolling or sliding. These components are not merely pieces of timber used to complete the pallet dimensions. Their sections, spacing, and connections must be determined according to product weight, base geometry, and forces that may arise during transport.
The number and position of the main skids are planned according to the product foot locations and forklift entries. If the load of a heavy product is concentrated near the center of the pallet, two edge skids alone may not be sufficient and an additional central support may be required. In long pallets, bending effects can increase as the total length and spacing between skids increase. Skid sections must be evaluated not only according to total product weight but also according to the point forces applied by forklift tines. If the heavy side of the product is known, the skids and connections in that area can be reinforced.
Cross members distribute product loads between the skids and provide strong connection areas for chocks. When there are insufficient cross members beneath product feet or the chassis, loads may be transferred to thin surface boards. If bolted securing is used, holes should be prepared according to the centerline of the structural cross members. Cross-member spacing should be arranged according to actual load points rather than distributed evenly only according to the pallet’s external dimensions. If a product’s four feet carry different loads, the supports beneath the heavier feet can be strengthened. This approach creates localized capacity without making the entire pallet unnecessarily heavy.
Stop chocks restrict forward, backward, and lateral movement of the product on the pallet. The chock shape must match the product base geometry and must not apply uncontrolled pressure to sensitive surfaces. For wheeled products, suitable stops can be positioned in front of and behind each wheel; wheel brakes should not be regarded as transport securing by themselves. Chocks must not extend into forklift tine paths or pallet rack support areas. At the destination, the chocks should be accessible and removable in a safe sequence when the product is taken off the pallet.
Cradle chocks used for cylindrical loads create a support geometry that prevents rolling. For rolls, reels, tanks, pipes, and similar products, the chock angle should be determined according to the product diameter. If the contact surface is too narrow, the product weight may become concentrated in a small area; if the support is excessively wide, unnecessary pallet space may be consumed. Felt, rubber, or another suitable protective layer may be used between the product and the timber. When multiple cylindrical loads are transported on the same pallet, separators and securing arrangements must restrict the movement of each item independently.
Skid height and bottom clearance determine forklift or pallet truck entry. A channel exactly equal to tine thickness may be insufficient because of site tolerances. Controlled working clearance should be provided without unnecessarily increasing the pallet’s total height and tare weight. Two-way entry can provide a continuous skid arrangement, while four-way entry may require a block-based or channelled base design. Additional reinforcement must be planned so that structural sections are not weakened when four-way entry is created. It should not be assumed that every entry direction has the same capacity.
The physical condition of the timber used for chocks and skids affects transport performance. Structural components should not contain severe cracks, warping, loose knots, or moisture-related deformation. On reusable pallets, forklift impacts may damage skid ends and channel edges in particular. Chock connections should be checked for loosening before every use. For export shipments, ISPM 15 requirements should be evaluated for solid wood skids, cross members, and chocks according to the destination route. Components of unknown origin added later may affect pallet traceability.
Functional Roles of the Chock and Skid System
Skids transfer the load to handling equipment, cross members distribute forces across the base, and chocks limit product movement and rolling.
To request a custom-size pallet quotation, the product’s bottom view, foot spacing, net weight, heavy side, forklift direction, and securing requirements should be provided. The technical drawing should separately show the main skids, cross members, product contact points, chock boundaries, and tine channels. After pallet completion, it should be verified that the product sits correctly against the chocks, the connections reach structural areas, and forklift entries are free from obstruction. Planning the chock and skid structure within the same load path increases pallet capacity while helping the product remain in its defined position throughout shipment.
Forklift Entry Direction
Forklift entry direction determines from which sides a custom-size pallet can be lifted safely at the production facility, warehouse, vehicle loading area, and destination. Whether the pallet provides two-way or four-way entry is not merely a matter of convenience; it directly affects the continuity of the main skids, the placement of cross members, and carrying capacity. When the product is long, wide, or has an off-center center of gravity, lifting from every direction may not provide the same level of safety. For this reason, entry direction must be designed together with product dimensions, load distribution, and the forklift specifications used on site.
With two-way forklift entry, the tines approach the pallet from two opposite sides. Allowing the main skids to remain continuous can create a strong load-bearing line for long and heavy loads. However, operational flexibility may decrease in narrow warehouse aisles or at container doors where the pallet cannot be turned into the correct orientation. Approach areas at both the dispatch and destination facilities should be reviewed in advance. If the pallet can only be lifted from a specific direction, this should be shown with visible markings on the outer surface. Forklift entry from a nonstructural side may damage the base components.
Four-way forklift entry provides operational flexibility by allowing the pallet to be lifted from different sides during warehouse movement and vehicle loading. However, creating cross-direction tine channels may require the main skids to be cut, a block-based structure to be used, or load-bearing members to be positioned at different levels. For heavy loads, these structural changes may require larger timber sections, additional blocks, and reinforced connections. Ease of use must not be considered separately from carrying capacity in a four-way pallet design. The load path for each entry direction should be shown separately on the technical plan.
Tine length is a decisive factor when selecting the correct entry direction. When entering a wide custom pallet from the short side, the tines may not reach the center of gravity. Entering from the long side may provide more balanced lifting depending on the pallet geometry. If standard tines support only the front portion of the pallet, the load center moves farther from the forklift body and the usable equipment capacity decreases. Fork extensions should not be assumed suitable for every application. Pallet dimensions and forklift tine length should be compared before production.
The clear height and width of tine channels should be determined by considering actual site tolerances. Clearance exactly equal to tine thickness may be insufficient because of floor slope, timber tolerances, or pallet deformation. Controlled entry clearance should be provided without unnecessarily increasing pallet height and tare weight. Center-to-center channel spacing must be compatible with the forklift’s adjustable tine range. Channels placed too close together may reduce lateral stability of a wide load, while channels placed too far apart may exceed the adjustment limits of some forklifts.
If pallet trucks will be used, entry direction must not be designed only around forklift geometry. Pallet truck wheels must not interfere with bottom blocks and cross members, the tines must reach the load center, and the full lifting motion must be possible. A standard pallet truck may be inadequate for very long or wide custom pallets. Cases where the pallet can be transported only by forklift should be communicated clearly to purchasing and site teams. The absence of a suitable forklift at the destination may prevent unloading or lead to temporary and unsuitable handling methods.
Forklift entry direction must be planned together with vehicle and container layout. If only one side remains accessible after the pallet is loaded, the unloading equipment at the destination must be able to use that side. Closely placing pallets side by side may block the entry faces and alter the unloading sequence. The order in which products will be unloaded should be included in the loading plan. When maneuvering space is limited at the container door, the primary entry direction can be positioned toward the door. Load-securing elements inside the vehicle must not block the tine channels.
Key Data for the Forklift Entry Plan
Pallet dimensions, gross weight, center of gravity, tine length and thickness, adjustable spacing, warehouse approach conditions, and vehicle layout must be evaluated together.
When requesting a custom-size pallet quotation, forklift types, approximate tine dimensions, pallet truck use, warehouse aisle conditions, and container loading methods at both dispatch and destination points should be provided. The technical drawing should clearly show two-way or four-way entries, channel dimensions, the primary lifting direction, and the heavy side of the product. After production, it must be verified that no fasteners, chocks, or product components obstruct the entry channels. Defining the forklift direction within the same plan as the product weight and base structure reduces loading time while limiting balance and structural problems caused by lifting from the wrong side.
Racking and Warehouse System Compatibility
Compatibility between a custom-size pallet and the racking and warehouse system is important not only for product transport safety but also for warehouse capacity and operational continuity. A pallet designed for the product may be moved safely by forklift but may still be unusable in storage if it does not rest on the rack beams through the correct points. Standard racking systems are generally planned around defined pallet dimensions, entry directions, and support spans. The custom pallet’s external width, length, bottom skid arrangement, and gross weight must be checked together with the rack specifications. Incompatibility identified after production may require separate floor space, rack modifications, or a replacement pallet.
The first racking compatibility check is to determine which structural components of the pallet will rest on the rack beams. When used on the floor, a large portion of the pallet’s bottom surface may be supported; on a rack, the load is usually carried across specific beam spans. This creates different bending forces in the main skids and cross members. If the rack beam spacing does not align with the structural members beneath the product feet, the load may be transferred to thin top boards. The rack beam positions and pallet orientation should be shown clearly in the custom pallet plan. A carrying capacity stated for floor use must not automatically be assumed valid for rack use.
Placing the pallet in the rack with either the short or long side facing forward changes the working direction of the structural members. If the main skids are designed to remain continuous in a specific direction, storing the pallet in the opposite orientation may be unsuitable. The rack entry side and lifting direction can be marked on the pallet so the forklift operator selects the correct orientation. Rack bay width must accommodate not only the pallet’s external dimensions but also the side clearance required during placement. Product or packaging overhang may contact rack uprights or neighboring loads. Actual rack dimensions must be calculated using the complete loaded profile, including the product.
Rack height and load profile affect the vertical use of warehouse space. Pallet height, product height, upper protection, and forklift placement tolerance must be evaluated together. Raising the product unnecessarily on the pallet may prevent it from fitting in the available rack bay or interfere with clearance required for sprinkler systems. Loads with irregular geometry and a high center of gravity may create different operational risks at upper rack levels. Product gross weight and center of gravity should be considered when selecting the rack location. Heavy loads should not be placed randomly based only on available empty space.
Warehouse aisles and forklift maneuvering space must be compatible with the custom pallet’s external dimensions. A pallet that is longer or wider than a EURO pallet may pass closer to racks and other loads while turning. Forklift tines must reach the load center without contacting the load or structure behind the rack. If the pallet can only be lifted from two directions, aisle and rack layout must provide access to the correct entry side. Four-way entry offers flexibility, but the recommended primary direction may still need to be preserved because of the heavy side of the product. Separate and clearly identified locations can be assigned to custom pallets in the warehouse plan.
Automated warehouses and conveyor systems require more detailed compatibility with the pallet’s bottom geometry. Roller or chain spacing must align with the pallet skids and create a continuous contact surface along the movement path. Sensor detection edges and centering components must match the external dimensions. Chocks or projections beneath the pallet may catch on conveyor mechanisms. A deformed or out-of-tolerance pallet can cause system downtime. For custom pallets used in automated systems, drawing review alone should not be considered sufficient; a sample application should be performed whenever possible.
Warehouse floor stacking and non-rack storage should be planned together with the racking system. If the custom pallet will wait outside the rack, the required floor area, permitted floor load, and forklift access must be defined. Pallets should be stacked only when both the product packaging and pallet structure are designed to carry the upper load. Pallets with different dimensions should not be stacked in an unstable arrangement. The supporting area of the lower pallet and the skids of the upper pallet should align vertically. Temporary floor stacking caused by high rack occupancy must not override safe stacking limits.
Information Required for Warehouse Compatibility
Rack bay dimensions, beam spacing, pallet orientation, rack capacity, aisle width, forklift specifications, conveyor structure, and completed load dimensions must be evaluated together.
Before ordering a custom-size pallet, rack drawings, beam spacing, forklift entry directions, and automation information from both dispatch and destination warehouses should be provided. The pallet plan should show the position of the main skids on the rack beams, the product center of gravity, and the permitted storage orientation. If the warehouse system cannot accept the custom pallet, product placement, pallet dimensions, or rack supports can be reconsidered before production. Including racking and warehouse compatibility in the design process helps ensure that the pallet can be used reliably not only in transport but also during receiving, storage, line feeding, and shipment preparation.
Heat Treatment Requirements
If a custom-size pallet will be used for export shipment, the need for heat treatment under ISPM 15 must be evaluated for solid wood skids, cross members, chocks, and upper load-bearing components. Whether the pallet is standard or custom size does not by itself change this requirement. The assessment depends on the type of timber used, the destination country, and the shipping route. Solid wood packaging materials can carry harmful organisms between countries when appropriate controls are not applied. Therefore, suitable material selection, approved treatment, IPPC marking, and production traceability must be handled within the same process.
Not only the externally visible boards but all solid wood components of the custom pallet must be included in the assessment. Main skids, cross members, wheel or cylinder stops, blocks beneath bolted connections, and securing chocks added later are all parts of the same pallet. Adding a support of unknown origin on site to a treated pallet may affect the compliance chain. Treated and untreated timber should be stored separately in the production area, and the source group of every cut component must be traceable. A small chock should be evaluated with the same care as a main load-bearing skid.
Under conventional heat treatment, the entire cross-section of solid wood, including the core, must reach at least 56°C and remain at that level continuously for a minimum of 30 minutes. Thick skids and blocks may take longer than thin pallet boards to reach the target temperature. Treatment should not be evaluated solely according to the furnace air temperature. Timber species, thickness, initial temperature, moisture condition, and airflow affect treatment duration. When the approved process is completed, conventional heat treatment is identified by the HT code within the IPPC mark.
The IPPC mark consists of the symbol, a two-letter country code, the authorized producer or treatment provider code, and the treatment abbreviation. For pallets prepared under the authorized system in Türkiye, the TR country code, the relevant facility number, and the HT treatment code must be legible together. The IPPC symbol or the letters HT alone do not constitute a complete mark. The marking must be applied to a visible, permanent, and readable surface. Before shipment, it should be checked whether product placement or stretch wrapping completely covers the mark.
Plywood, OSB, and similar processed wood-based materials may be treated differently from solid wood; however, the structural base of custom-size pallets usually consists of solid wood skids and cross members. Adding a plywood sheet to the top surface does not eliminate the treatment requirement for the solid wood components beneath it. A metal frame or plastic base may create a different material scope. All pallet components should be identified by material type in the quotation. This allows the heat-treatment decision to be based on the actual structural composition rather than external appearance.
For reused or repaired custom pallets, the condition of the existing IPPC mark must be checked separately. The presence of an old stamp does not confirm that all components replaced later are compliant. Replacing a broken skid, cross member, or chock with timber of unknown origin may compromise traceability. Multiple codes from different facilities on the same pallet may create uncertainty about production and repair history. The pallet’s physical carrying capacity and phytosanitary compliance should be inspected together before reuse. Repairs must be performed under authorized application conditions.
Heat treatment does not automatically increase the pallet’s mechanical capacity, water resistance, or moisture protection for the product. The HT code identifies a phytosanitary treatment applied to solid wood. Skid sections, fasteners, forklift channels, and chock structures must still be designed separately according to product weight. For sea shipments, metal products may require barrier film, desiccant packs, or another suitable protective method against corrosion. Physical performance can also be affected if treated timber becomes wet outdoors or is stored under unsuitable conditions. Heat treatment and transport design are complementary controls with different objectives.
Scope of the Heat Treatment Check
Main skids, cross members, chocks, blocks, and other solid wood components used during loading must be evaluated within the same ISPM 15 compliance and traceability system.
When ordering a custom-size pallet, the destination country, transit route, export date, and any additional securing components to be used on site should be provided together with the product dimensions and weight. The quotation should clearly state the heat treatment, IPPC marking, and relevant production scope. After pallet completion, the legibility of the markings, consistency of facility codes, and absence of unsuitable timber added later must be checked. Determining the heat-treatment requirement at the beginning of the order reduces the need to modify or rebuild the pallet after production and supports a more predictable export process.
Pre-Order Technical Data Checklist
Obtaining an accurate price and a feasible design for a custom-size pallet depends on providing complete technical information about both the product and the logistics process before ordering. Stating only that a “1500 × 1000 mm pallet” is required is not sufficient to determine structural sections, forklift direction, and product securing. Pallets with the same external dimensions may require completely different structures because of differences in product weight and operating conditions. When the product’s net dimensions, maximum weight, base contact points, storage method, and shipping route are provided together, the quotation can be based on actual material and labor requirements. Incomplete data may lead to design changes and price revisions before production.
The first part of the technical data list should include the product’s maximum width, length, and height in its shipment position. Measurements should be provided in millimeters and in the order width × length × height. It must be clearly stated whether the values belong to the product, the requested pallet dimensions, or the completed load envelope. Motors, pipes, connection arms, control panels, and protective projections must be included in the measurements. If removable components are present, it should be clarified whether they will be transported on the same pallet or in separate packaging. If the product will be shipped in an orientation different from its normal operating position, the surface placed on the pallet must be shown on the technical drawing.
The second data group consists of product weight and base loads. In addition to net weight, the maximum possible value including components added during production or shipment should be stated. Outside-to-outside foot spacing, the contact area of each foot, chassis width, and bolt holes can be shown on the bottom-view drawing. If the product contains a heavy motor or body section, the approximate center of gravity should be marked. When multiple products will be transported on one pallet, the weight and position of each item must be provided separately. This information allows skid, cross-member, and connection sections to be determined according to the actual load points.
Product Dimensions
Maximum width, length, height, transport orientation, and projecting parts should be specified.
Weight and Base Structure
Net weight, maximum weight, foot positions, and center of gravity should be provided.
Handling Information
Forklift, pallet truck, crane, and permitted entry directions should be explained.
Warehouse and Shipment
Racking, conveyors, vehicles, containers, and stacking conditions should be specified.
Forklift and pallet truck information is used to prepare the pallet base structure. The need for two-way or four-way entry, along with equipment tine length, thickness, and adjustable spacing, should be provided. Forklift carrying capacity must support the combined gross weight of the pallet and product. If the custom pallet is wide or long, standard tines may not reach the center of gravity. When only pallet trucks are available at the destination, compatibility of the bottom blocks and wheel paths must be checked. If crane handling is planned, lifting points and sling directions must also be specified.
Racking and warehouse system data ensures that the pallet can be used safely not only on the floor but also during storage. Rack bay width and height, beam spacing, permitted load, and pallet entry orientation should be provided. If automated storage or conveyors will be used, roller spacing, sensor locations, and limits related to the pallet’s bottom surface must be specified. When pallets are expected to be stacked, the number of levels and upper-load weight must be stated. A custom pallet incompatible with the standard warehouse may require dedicated floor space or additional pallet supports. Identifying these requirements only after production may affect warehouse capacity.
Product securing and protection expectations should be included as a separate section of the technical data list. It should be stated whether the product can be bolted to the pallet, which chassis areas can receive support, and which surfaces are sensitive. Wheeled products may require stop chocks, cylindrical loads may require cradle supports, and long components may require intermediate supports. Straps, banding, corner protectors, anti-slip layers, and surface protection should be selected according to product characteristics. If direct contact between the product and timber must be avoided, the thickness of felt, rubber, or another intermediate material must be included in the dimensional plan.
Shipment and export information affects both pallet material selection and external dimensions. Vehicle or container type, number of pallets in the same shipment, loading direction, and permitted maximum external dimensions should be provided. If the product will be wrapped with protective packaging, the completed load envelope must be calculated including those layers. When solid wood is used for export, ISPM 15 requirements should be evaluated according to the destination country and transit route. Heat treatment and IPPC marking requirements must be stated clearly in the quotation scope. If additional timber supports will be added on site, these parts must also be included in the compliance chain.
Items to Verify Before Order Approval
Product dimensions, weight distribution, base contacts, securing, forklift direction, racking system, vehicle layout, stacking, and export requirements must be approved within the same technical scope.
Current technical drawings, photographs from different angles, and visuals showing measurement points should be attached to the quotation request. In the pallet plan prepared by the manufacturer, external dimensions, skid and cross-member sections, chocks, forklift channels, product boundaries, and connection points must be checked individually. When comparing quotations, the review should consider not only total price but also whether the same carrying capacity and operating conditions are included. Preparing the pre-order technical data list completely helps the custom-size pallet match both the product and warehouse system from the first production cycle while reducing costly on-site modifications later.