Pallet Selection Guide: Wood, Plastic, or Metal?

Choosing the right pallet material affects your shipping costs, product protection, hygiene compliance, and environmental footprint. This guide compares wood, plastic, and metal pallets across the factors that matter most to your operation.

Wood Pallets

Wood pallets are the most widely used pallet type in North America, accounting for over 90% of all pallets in circulation. They are affordable, readily available, easily repairable, and recyclable.

Pros

• Lowest upfront cost ($8-$25 new, $4-$15 used)
• Widely available in standard and custom sizes
• Easily repairable — damaged boards can be replaced
• Good weight capacity (2,500-4,500 lbs for standard GMA pallets)
• Recyclable and biodegradable
• High friction surface helps prevent load shifting

Cons

• Susceptible to moisture, mold, and pest infestation
• Requires ISPM-15 heat treatment for international shipping
• Heavier than plastic (45-55 lbs for a standard 48x40 pallet)
• Splinters and nails can damage products or injure workers
• Inconsistent quality, especially for used pallets

Plastic Pallets

Plastic pallets are growing in popularity, especially in industries with strict hygiene requirements. They offer consistency, durability, and cleanliness advantages over wood.

Pros

• Impervious to moisture, mold, and pests
• Consistent dimensions and weight
• Lighter than wood (35-45 lbs typically)
• No splinters or nails — safer handling
• Easy to clean and sanitize
• Exempt from ISPM-15 requirements
• Long lifespan (10+ years with proper use)

Cons

• Higher upfront cost ($30-$100+ each)
• More difficult to repair than wood
• Lower friction surface — loads may shift
• Not compatible with all racking systems
• Limited recycling options in some areas

Metal Pallets

Metal pallets (steel or aluminum) are the most durable option but also the most expensive. They are used in specialized applications where other pallet types are insufficient.

Pros

• Extremely durable — lifespan of 15-20+ years
• Highest weight capacity (up to 6,000+ lbs)
• Impervious to moisture, pests, and chemicals
• Easy to clean and sanitize
• Excellent for automated systems and racking
• Fully recyclable with high scrap value

Cons

• Highest cost ($75-$200+ each)
• Heaviest option (50-70 lbs for steel)
• Can rust if not properly coated (steel)
• Cold temperature conduction issues
• Not practical for one-way shipping

Decision Matrix

Use these guidelines to choose the right pallet material for your application:

• One-way domestic shipping → Used wood pallets (lowest cost)
• Recurring internal use → New wood or plastic (durability matters)
• Food/pharmaceutical → Plastic (hygiene compliance)
• International export → Heat-treated wood or plastic (ISPM-15)
• Heavy industrial → Metal or heavy-duty wood (weight capacity)
• Automated warehouse → Plastic or metal (consistent dimensions required)
• Budget-conscious → Used wood pallets (best value)