Product · New build
New pallets, built here, to your drawing
Sometimes recycled is the wrong answer — a cleanroom, a first export shipment, a footprint nobody else uses. We build new too, and we build it in the same yard.
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RePallet Co. builds new wooden pallets to specification in Denver, in stringer or block construction, any footprint, from new graded lumber or reclaimed deck stock. Heat treatment and IPPC stamping are available for export.
Lead time is typically one to three weeks depending on quantity and whether the footprint is one we already hold a jig for. New 48x40 GMA runs roughly $17–$26 depending on specification and lumber pricing.
When new genuinely beats recycled
We sell recycled pallets for a living, so take this as more credible than it would be from a new-pallet manufacturer: there are real cases where new is correct, and pretending otherwise would cost you money later.
- Cleanroom, pharmaceutical or direct-food environments where unknown history is unacceptable.
- First export shipments where a rejected container costs far more than the pallet delta.
- Automated systems with tight tolerances — new pallets are dimensionally consistent to the millimetre.
- Unusual footprints that simply do not exist in the recycled stream.
- Engineered load requirements where you need a documented, calculated rating rather than an observed one.
- Brand-facing display units where appearance is part of the product.
Specification options
| Variable | Options | Affects |
|---|---|---|
| Construction | Stringer (2- or 4-way) or block (full 4-way) | Entry, strength, cost |
| Deck boards | 5, 7 or 9 top boards; flush or overhang | Load spread, weight, cost |
| Board thickness | 1/2", 5/8", 3/4" | Capacity and durability |
| Species | Hardwood, SYP, SPF, mixed | Weight, strength, price |
| Fasteners | Ring-shank, screw-shank, stapled | Repairability and lifespan |
| Bottom deck | Full, 3-board, perimeter, none | Floor vs rack behaviour |
| Treatment | Untreated, KD, HT/ISPM 15 | Export eligibility |
| Finish | Raw, sanded, stencilled, painted | Appearance and branding |
If that list feels like a lot, ignore it and tell us what the pallet has to carry, where it goes and how it is handled. We will draft the specification and send it back for approval — that is the normal route and it produces better pallets than a customer working from a catalogue.
New from reclaimed lumber
Our favourite product, and the one that confuses people most: a genuinely new pallet, built to a fresh specification, out of boards recovered from pallets that reached the end of their lives. It is new in every sense that matters structurally, and the carbon footprint is a fraction of a conventionally new unit.
It works best for half pallets, display bases, skids and light-duty footprints. For heavy engineered loads we use new graded structural timber, because reclaimed boards do not carry a documented grade stamp and honesty about that matters more than the sale.
Writing a new-pallet specification
You do not need to fill this in. Send us the load, the handling and the destination and we will draft it. But if you want to arrive with a specification of your own, this is the full set of decisions.
| Field | Options | Default we would choose |
|---|---|---|
| Footprint | Any | 48" x 40" unless you say otherwise |
| Construction | Stringer 2-way, stringer 4-way, block | Notched stringer |
| Top deck boards | 5, 7, 9, butted | 7 |
| Bottom deck | Full, 3-board, perimeter, none | 3-board |
| Board thickness | 1/2", 5/8", 3/4" | 5/8" top, 1/2" bottom |
| Stringer section | 1.5" x 3.5", 1.5" x 5.5" | 1.5" x 3.5" |
| Species | Hardwood, SYP, SPF, mixed | Mixed hardwood |
| Fasteners | Ring-shank, screw-shank, staples | Ring-shank |
| Overhang | Flush, winged | Flush |
| Chamfer | Yes / no | Yes on both lead boards |
| Treatment | None, KD, HT / ISPM 15 | None for domestic |
| Finish | Raw, sanded, stencilled, painted | Raw |
| Marking | None, stencil, branded, numbered | None |
Engineered ratings, and what we will and will not certify
There is an important distinction here that a lot of suppliers blur, and it matters legally as well as practically.
Observed ratings
What we publish for recycled pallets. Working figures drawn from experience with that construction in that condition. Honest, useful, and not a certification.
Calculated ratings
For new pallets built to a specified design, we can state a calculated capacity based on member sizes, species and span. Documented and defensible.
Tested ratings
Where a third-party test is genuinely required — high-value automated systems, insurance requirements — we will arrange it and say plainly that it is a third party doing it.
If a supplier offers a certified load rating on a recycled pallet, ask what was tested and by whom. The honest answer for used stock is almost always an observed figure, and calling it something else does not help anyone when a rack fails.
Racking is a system property
No pallet has a racking capacity on its own. It has a capacity across a given unsupported span, and your beam spacing is part of the calculation. A pallet rated for 2,500 lb on a 44" span may be well under 2,000 lb on 52". This is why we ask about your rack before quoting anything for racking.
Lead times, minimums and holding stock
| Scenario | Minimum | Lead time |
|---|---|---|
| Existing jig, standard spec | 50 units | 5 – 8 working days |
| Existing jig, modified spec | 50 units | 1 – 2 weeks |
| New design, prototype | 1 unit | 3 – 5 working days |
| New design, production | 100 units | 2 – 3 weeks |
| Heat treated for export | add 3 – 5 days | — |
| Held against a forecast | Agreed buffer | Next day from stock |
For anything you use continuously, holding stock against a forecast is the answer to lead time. We ring-fence an agreed buffer and you draw against it, which turns a three-week build into a next-day pick. It costs nothing beyond the commitment to a forecast.
When to build new from reclaimed stock
Half pallets, quarter pallets, display bases, skids and light-duty footprints all build beautifully from recovered deck boards — roughly 62% lower embodied carbon and $4 to $7 a unit cheaper. Heavy engineered loads get new graded structural timber, because reclaimed boards do not carry a grade stamp and we are not going to pretend otherwise.
Questions people actually ask
What is the minimum order for new pallets?
How long does a new pallet last?
Can you match an existing pallet?
Do new pallets need heat treatment for domestic use?
Can you match a competitor's pallet exactly?
Do new pallets need a break-in period?
Can you number or serialise pallets?
What is the environmental case for new pallets?
Do you build to CHEP or PECO specifications?
Let's keep your pallets in the loop
Whether you have 40 broken cores behind the dock or need 4,000 Grade A pallets a month, the conversation starts the same way.