Plastic pallets are quickly replacing traditional wooden ones across warehouses and logistics chains. If you’re planning to get into pallet manufacturing, Daoben Machinery’s Plastic Pallet Machine solutions offer you the performance, durability, and ROI you need. Here’s how the production process works—and how you can scale fast with the right machinery.
Introduction:
Let’s face it—plastic industrial pallets are taking over warehouses, logistics hubs, cold storage facilities, and manufacturing units worldwide. They’re more durable than wood, easier to clean, resistant to moisture and pests, and fully recyclable.
But have you ever stopped to think: How are these strong, lightweight, reusable pallets actually made?
Well, you’re in the right place. In this guide, we’ll take a deep dive into the plastic pallet production process, and more importantly, how Daoben Machinery’s Plastic Pallet Machine—ranging from 30 Ton to a whopping 4000 Ton—can help you manufacture high-quality pallets at scale.
Whether you’re a newcomer or looking to expand your current production line, stick around. We’re about to unpack some seriously valuable insights!
Why Plastic Pallets Are in High Demand
First, let’s talk about why plastic pallets are booming in global markets:
Hygienic and easy to clean
Weather and moisture-resistant
Longer lifespan than wood
Lightweight yet durable
Standardized dimensions
Perfect for automated warehouses
Compliant with global export regulations
With E-commerce, cold chain logistics, and global shipping growing fast, plastic pallets are a goldmine opportunity for manufacturers.
Step-by-Step: How To Make Plastic Industrial Pallets
Creating a top-quality plastic pallet takes more than just melting plastic and pouring it into a mold. Here’s the full process simplified:
Step 1: Pallet Design & Engineering
Before anything else, you need a well-thought-out design. Plastic pallets come in various types:
- Single-face or double-face
- Rackable or stackable
- Nestable for space-saving
- With or without steel reinforcements
At Daoben, we work closely with mold designers to make sure:
- The load-bearing capacity is accurate
- The material flow is balanced
- Venting, cooling, and ejecting are all optimized
Engineering the right design ensures that your pallets don’t crack under pressure (literally).
Step 2: Building the Injection Mould
Once the design is ready, the next step is building a heavy-duty mold, usually made from P20 or H13 steel. Why?
Because pallet molds are:
- Massive in size
- Handle high injection pressure
- Require complex cooling channels
- Need to last through hundreds of thousands of cycles
The mold can weigh several tons and is designed to withstand very high clamping forces, especially for two-cavity designs (which double your output).
Step 3: Choosing the Right Plastic Pallet Machine
Here’s where Daoben Machinery comes into play.
Depending on the size and weight of the pallet, you’ll need a injection molding machine with the right tonnage. Here’s a general guide:
| Pallet Type | Suggested Machine Size |
|---|---|
| Small pallet (800×600 mm) | 1000–1300 Ton |
| Standard Euro pallet (1200×800 mm) | 1600–2000 Ton |
| Industrial pallet (1200×1000 mm) | 2000–3000 Ton |
| Extra heavy-duty pallet | 3200–4000 Ton |
Pro Tip: Always match your mold size and injection volume to the machine’s capacity. Too small = pressure problems. Too big = wasted energy.
Step 4: The Injection Molding Process
Once the machine and mold are in sync, it’s go-time! Here’s how it flows:
- Feeding: Plastic resin (usually HDPE or PP) is poured into the hopper.
- Melting: The material is heated and mixed inside the barrel.
- Injection: Molten plastic is injected into the mold cavity at high pressure.
- Cooling: The mold is cooled using a water circulation system to solidify the plastic.
- Ejection: The machine automatically ejects the finished pallet.
Cycle times can vary depending on size but typically range from 90 to 180 seconds per cycle.
And thanks to Daoben’s servo-hydraulic technology, you’ll save up to 60% in energy costs compared to conventional systems.
Why Choose Daoben Machinery for Plastic Pallet Production?
Great question! Here’s why hundreds of manufacturers trust Daoben to power their pallet lines:
Wide Tonnage Range (30–4000 Ton)
From small parts to mega pallets, Daoben has you covered—without overpaying for unnecessary tonnage.
High-Speed, Energy-Saving Machines
Our servo systems are designed for high injection speeds, faster cooling cycles, and lower energy bills. The perfect trio.
User-Friendly Controls
All machines come with a smart PLC touchscreen control system that operators love. Easy monitoring, quick adjustments, and minimal training needed.
Rugged Machine Build
Pallet molding is tough work. That’s why our machines are built with reinforced platens, stronger tie bars, and high-load tolerance systems.
Global Export Support
Whether you’re in Africa, Southeast Asia, the Middle East, Europe, or Latin America, we provide:
- Door-to-door shipping
- Installation & training
- After-sales service and parts supply
Common Materials for Plastic Pallets
You’ve got machine power—but what about the plastic itself?
The most commonly used materials are:
- HDPE (High-Density Polyethylene) – Tough, flexible, UV-resistant
- PP (Polypropylene) – Higher stiffness, temperature resistant
- Recycled plastic blends – Great for eco-friendly production
Daoben molding machines handle both virgin and recycled materials like a champ—helping you cut costs without sacrificing quality.
Pallet Types You Can Manufacture with Daoben Machines
✔️ Standard industrial pallets (1200×1000 mm)
✔️ Euro pallets (1200×800 mm)
✔️ Nestable pallets
✔️ Rackable pallets with steel bars
✔️ Heavy-duty pallets for export
✔️ Hygienic pallets for food & pharma
FAQs – Everything You Wanted to Know
Q1: How long does a plastic pallet mold last?
With proper maintenance, up to 1 million cycles or more.
Q2: Can I use recycled material?
Yes! Our machines are fully capable of processing recycled plastics.
Q3: How many pallets can I make in a day?
Depending on your cycle time and mold cavities, you can produce 200–800+ pallets/day on a single machine.
Q4: Do I need a chiller or auxiliary equipment?
Yes, we recommend using a chiller, hopper dryer, and auto loader for smoother production and consistent quality.
Q5: How much space do I need for installation?
For a 2000–3000 Ton machine, plan for at least 200–300 square meters, including mold movement and auxiliary space.
Let’s Build the Future of Pallet Production
So there you have it—a full walkthrough of how to make plastic industrial pallets, backed by expert-level machines from Daoben Machinery.
With more companies ditching wood and switching to plastic, now’s the perfect time to step into the game. And if you want machines that are:
- Reliable
- Energy-efficient
- Easy to operate
- Built for tough jobs
Then you already know who to call. Daoben Plastic Pallet Machine solutions are engineered to help you produce more, waste less, and grow faster.
