People often search for pallet racking types when they are trying to solve a storage problem, but the conversation quickly turns into pallets themselves. That makes sense. The pallet you use affects how well your racking performs, how safely loads sit on beams, how often you see product damage, and how smoothly forklifts can move inventory in and out of bays.
This guide focuses on the most common pallet types used in warehouses and how each one behaves in pallet racking. If you are planning new racking or trying to reduce rack damage and improve storage efficiency, the right pallet choice is part of the solution.
Why Pallet Type Matters in a Pallet Racking System
Pallets look simple, but their construction and consistency determine how stable your loads are in racking and how predictable your operation feels day to day.
Load capacity and rack ratings
Pallet racking beams and frames are designed for specific load capacities. If pallets are inconsistent in size, damaged, or built with weak deckboards, loads can shift, deflect, or concentrate weight in ways that increase risk. A strong racking system still depends on pallets that support the load correctly.
Pallet deflection and fall through risk
Some pallets flex more than others. Excess flex can cause cartons to lean or shift, and it can increase the chance of product falling through, especially when loads do not sit evenly across the beam span. This is one reason many warehouses add wire decking or pallet supports rather than relying on pallet quality alone.
Compatibility with wire decking and pallet supports
Wire decking improves safety and creates a more forgiving support surface for different pallet types. Some pallets, especially lighter designs, may require decking or additional supports to sit safely in racking. The goal is consistent load support across every bay, not just the good bays.
Forklift handling and throughput
Pallet design affects how quickly operators can enter, lift, and place loads. Stronger, consistent pallets reduce handling issues. Lower quality pallets increase hang ups, broken boards, and rework. Over time that slows putaway and picking and increases labor cost.
Cleanliness and environment
Food, beverage, medical, and other hygiene sensitive operations often choose pallets that are easier to clean. Moisture, humidity, and temperature extremes also influence pallet life. A pallet that performs fine in dry storage can fail faster in damp areas or outdoor staging.
Common Types of Pallets Used in Warehouses
There are five main pallet types commonly used today. Each has pros and cons, and each interacts differently with pallet racking based on load weight, environment, and workflow.
Wooden Pallets
Wooden pallets are the most common option in many warehouses. They are typically used for heavier products and for general storage where pallets are frequently reused. They come in many designs, including block pallets and stringer pallets, and quality can vary depending on whether they are new, recycled, or repaired.
Pros
- Large and long lasting
- Costs less on average compared to other pallet options
- Easy to repair
- Easy to install
- More resistance than plastic and metal pallets
- Can be recycled
- Can be reused and resold
Cons
- The high weight can be costly when it comes to shipping
- Hard to clean, which can lead to mold growth
Racking considerations
Wood pallets usually work well in selective pallet racking and standard warehouse storage. The biggest issue is consistency. Mixed pallet types and mixed repair quality can create uneven loading, damaged deckboards, and weak fork entry points. If your warehouse has a lot of repaired pallets, wire decking and rack protection often reduce damage and improve safety.
Lightweight Plywood Pallets
Lightweight plywood pallets are used to store light to medium weight materials. They are popular in some shipping workflows because they reduce transportation weight and can still provide good strength when manufactured well.
Pros
- Extremely strong and durable
- The light weight makes them great for shipping and transporting
- Smooth, spotless surface
Cons
- Can be difficult to store in racking
- Can suffer from water damage if left outside
Racking considerations
Plywood pallets can be challenging in racking if the pallet design does not provide solid support across beams or if the pallet flexes under load. They usually perform better when loads are consistent and weight is controlled. If plywood pallets are part of your operation, consider using wire decking or pallet supports to reduce flex and prevent fall through, especially on higher levels.
Plastic Pallets
Plastic pallets are common in industries that value cleanliness and durability. They can be a safe packing solution for shipping and are often used where washdown and hygiene standards matter.
Pros
- Corrosion and humidity resistant
- Recyclable
- Resistant to chemicals
- Long lifespan
- Safe to handle
- Easy to clean
Cons
- Not typically used for storage or shelving
- Higher cost compared to wooden pallets
Racking considerations
Plastic pallets vary widely by design. Some have solid decks, some have open decks, and some flex more than wood under load. In racking, that flex can create stability issues if loads are heavy or uneven. Plastic pallets can also slide more easily, so alignment and safe placement matter. Many warehouses use plastic pallets for shipping or clean areas and stick with wood for long term rack storage unless the plastic pallet design is built specifically for racking.
Presswood Pallets
Presswood pallets are molded from dried wood fibers. They form one solid piece due to high temperature and pressure. They are often chosen for export, one way shipping, and operations that need consistent sizing and stackability.
Pros
- Lightweight
- Good strength
- Recyclable
- Resistance to moisture
- Easily handled due to weight
- Can be stacked atop one another for convenience
Cons
- Susceptible to water damage if left outdoors
- Some warehouses are not ideal for this type of pallet
Racking considerations
Presswood pallets can be consistent and easy to stack, but their performance depends on the specific load and environment. If they are used in racking, you want to confirm they are rated appropriately for the weight you store and that the design supports the load across beams. They generally perform best indoors in controlled conditions and with predictable load weights.
Corrugated Cardboard Pallets
Corrugated cardboard pallets are formed of a framework of corrugated cardboard sheets. They are lightweight and are often used for one way shipments or light duty loads. Some designs can carry surprisingly high weight for their category, but they are still more sensitive to moisture and rough handling.
Pros
- Easy to handle and transport
- Exceptionally strong
- Customizable
- Recyclable
Cons
- Will not hold up in outdoor weather
- Cannot be used for heavier materials
Racking considerations
Cardboard pallets typically require a controlled environment and careful handling. In pallet racking, they often need full support such as wire decking or pallet supports, especially if the pallet footprint does not sit firmly on the beams. They are usually best for short term indoor storage and shipping workflows rather than long term high level storage.
Matching Pallet Types to Pallet Racking Use Cases
If you are deciding whether your current pallets are a good fit for your racking, focus on how your inventory behaves and how consistent the pallets are across the building.
When wooden pallets are the best fit
Wood pallets are usually the most forgiving option for mixed loads and long term storage. They work well when you have many SKUs, variable pallet weights, and a standard selective rack layout. They are also easier to repair, which helps warehouses that cycle pallets heavily.
When plastic pallets make sense
Plastic pallets shine in clean environments, humid areas, and operations where pallets must be washed or where chemical resistance matters. If plastic pallets are used for rack storage, confirm the pallet design is intended for racking and does not create excess flex. Consistency matters more than material.
When lightweight pallets are best kept to shipping
Plywood and cardboard pallets often work best in shipping lanes, staging, and one way workflows. They can be stored in racking in some facilities, but they usually need stricter load control and better support surfaces to avoid deflection issues.
When presswood pallets are a good compromise
Presswood pallets can be a good option for consistent sizing and export workflows. They can be viable in racking when loads are controlled and the environment is dry, but they are not ideal for outdoor storage or heavy impact handling.
Common Problems Caused by the Wrong Pallet Choice
Even strong racking struggles when pallets are inconsistent or poorly matched to the load.
Beam overload and deflection
When pallets sag or loads concentrate on weak points, beams can deflect more than expected. Over time this increases rack stress and creates safety risks.
Product fall through and load shifts
Uneven decks and damaged boards increase the chance of cartons tipping or falling. This is especially risky on higher levels and in areas where people work near storage bays.
More rack damage and forklift impacts
Broken deckboards, poor fork entry, and unstable loads lead to more mishandling. That increases collisions, bent uprights, damaged beams, and ongoing repair costs.
Inspection failures and compliance issues
Damaged components, missing support surfaces, and unstable loads can lead to operational restrictions. Regular inspections help catch this early, but the best prevention is choosing pallets that fit your storage system.
How to Choose the Right Pallet for Your Warehouse
If you want better performance from your racking, your pallet choice should be intentional, not accidental.
Start with load weight and distribution
Confirm what a typical pallet weighs and whether weight is evenly distributed. A pallet that works for uniform cases might fail for loads with concentrated weight.
Consider how long pallets sit in storage
Short term staging pallets can be lighter. Long term rack storage benefits from stronger, more consistent pallets.
Factor in environment and handling conditions
Humidity, washdown, outdoor staging, and cold storage all affect pallet life. Choose materials that match the environment.
Reduce variation whenever possible
Mixed pallet sizes and inconsistent quality increase handling problems and damage. Standardizing pallet type and quality across the warehouse is one of the fastest ways to improve stability and workflow.
Decide how you will handle pallet condition
If your operation uses repaired pallets, create a simple inspection habit. Remove broken pallets before they go into racking. That single step prevents a surprising amount of damage.
Pallet Racking by Storage Equipment Systems, Inc.
Storage Equipment Systems, Inc. was established in April of 1982. We are a distributor of warehouse equipment such as racks, shelving, conveyors, dock levelers, and many types of material handling equipment. We keep extensive inventory in our Phoenix warehouse, including pallet racks and the accessories that help warehouses store product safely and efficiently.
What differentiates Storage Equipment Systems is our care and concern for the customer. It is not only providing equipment. It is providing the right equipment. If you are evaluating pallet racks, upgrading your warehouse layout, or trying to reduce rack damage and improve storage performance, our team can help you choose solutions that fit your workflow.
Contact Storage Equipment Systems, Inc. today to talk through your warehouse storage goals and get a plan that supports safe and efficient operations.