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Custom pallets can solve many shipping and storage problems, but only if they are designed and handled correctly. In Surrey, the most common issues are poor sizing, overloads, moisture damage, forklift damage, and compliance mistakes, and most of them can be prevented with the right planning.
For warehouses, exporters, and manufacturers in Surrey, the key is choosing a pallet built for the load, the equipment, and the environment where it will be used.
Problem 1: Wrong Size or Poor Fit
One of the biggest issues with custom pallets is sizing them too loosely or too tightly. A pallet that does not match the product footprint can cause overhang, unstable stacking, and wasted trailer space.
How to avoid it:
- Measure the load carefully before ordering.
- Include packaging, shrink wrap, and any protruding parts.
- Confirm forklift entry and racking dimensions.
- Ask for a sample pallet before full production.
A precise fit improves safety and reduces damage during handling.
Problem 2: Overloading the Pallet
Even a well-built pallet can fail if it carries too much weight. Overloading can bend deck boards, split stringers, and cause the load to shift unexpectedly.
How to avoid it:
- Know the static and dynamic load limits.
- Choose reinforced construction for heavy products.
- Spread the weight evenly across the pallet surface.
- Train staff not to exceed rated capacity.
If your loads are heavy or uneven, the pallet should be designed for that from the start.
Problem 3: Moisture and Weather Damage
Surrey’s damp weather can affect wood pallets if they are stored outdoors or in poorly ventilated areas. Moisture can lead to warping, mold, or weakened boards.
How to avoid it:
- Store pallets indoors or under cover.
- Keep them off the ground on racks or blocks.
- Use heat-treated or properly dried lumber.
- Rotate older stock so pallets are not sitting unused for too long.
Good storage habits can extend pallet life and reduce repair costs.
Problem 4: Forklift Damage
Forklift impacts are a common cause of pallet failure. Misaligned forks, fast entries, and rough handling can crack boards and damage stringers.
How to avoid it:
- Train operators to enter pallets straight and slowly.
- Match pallet openings to your forklift setup.
- Remove damaged pallets from service immediately.
- Use stronger construction for high-traffic warehouse use.
Better handling practices protect both the pallet and the product on it.
Problem 5: Weak Construction for the Application
Some custom pallets are built well, but not for the right use. For example, a pallet designed for light warehouse storage may not hold up under heavy export loads or repeated racking.
How to avoid it:
- Match the design method to the job.
- Use block or double-face pallets for tougher applications.
- Add reinforcements where the load is concentrated.
- Ask your supplier for a recommendation based on real use, not just dimensions.
The right design method is just as important as the right size.
Problem 6: Export Compliance Mistakes
If your pallets are used for international shipping, they must meet heat-treatment and marking requirements. Missing stamps or incorrect treatment can cause customs delays or shipment rejection.
How to avoid it:
- Confirm whether your shipment requires ISPM-15 compliant pallets.
- Ask for heat-treated pallets when exporting.
- Verify that the marking is correct and visible.
- Do not repair export pallets without checking compliance rules.
Compliance is especially important for Surrey businesses shipping to other countries.
Problem 7: No Maintenance or Inspection Plan
Custom pallets last longer when they are checked regularly. Without inspections, small problems like loose nails, cracks, or warped boards can turn into full failures.
How to avoid it:
- Inspect pallets before each use or at set intervals.
- Pull damaged pallets from rotation right away.
- Keep a repair or replacement process in place.
- Track repeated failures to improve future designs.
A simple maintenance routine can prevent many expensive problems.
How AR Pallets Help
AR Pallets helps Surrey businesses avoid these common pallet problems by designing pallets around the real load, handling method, and environment. That includes custom sizing, stronger construction for heavy loads, and heat-treated options for export use.
Because the company is local, Surrey customers can also get faster support, better fit testing, and repeatable pallet specs for future orders.
FAQ
What is the most common problem with custom pallets?
The most common problem is poor sizing, which can lead to overhang, unstable stacking, and wasted space.
How can I tell if a pallet is overloaded?
If boards bow, stringers split, or the pallet shifts under normal handling, the load may be too heavy.
Do custom pallets need special storage?
Yes. Keeping them dry, elevated, and protected from moisture helps prevent warping and mold.
What causes forklift damage to pallets?
Fast entry, poor alignment, and rough handling are the most common causes.
How do I avoid export compliance problems?
Use heat-treated, ISPM-15 compliant pallets and make sure the marking is correct before shipping.
Get Safer Custom Pallets in Surrey
Surrey businesses can avoid most custom pallet problems with better design, safer handling, and regular inspection. A local supplier that understands load requirements, warehouse use, and export rules can help you get pallets that last longer and perform better.
Custom Pallet Support for Surrey Businesses
Trusted Custom Pallet Solutions in Surrey
Surrey businesses that want to avoid common custom pallet problems can rely on AR Pallets for practical designs, stronger builds, and export-ready options.
AR Pallets LTD, located at 12213 Industrial Rd, Surrey, BC V3V 3S1, Canada, helps you choose the right pallet size, construction, and treatment for your operation. Call (604) 367-7884 or email info.arpallets@gmail.com to request a quote, ask about pallet safety, or start your next custom order today.
