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ORBIS plastic pallets protect your product during picking, assembly, processing, storage and distribution in a wide variety of industries. Plastic pallets are an economic, environmental and efficient alternative to wood pallets or skids. Our solutions cover all standard pallet dimensions. ORBIS designs custom pallet solutions for moving, storing or displaying products at every point along your supply chain!
Reusable plastic pallets are engineered to make multiple trips through a supply chain rather than being discarded after a single use. Unlike wood pallets or corrugated skids that are typically used once and replaced, reusable pallets are designed for a defined service life measured in years and hundreds of cycles.
The distinction matters operationally. A single-use pallet is a per-shipment consumable cost. A reusable pallet is a capital asset that spreads its purchase cost across every trip it completes. The longer the service life and the more tightly controlled the return loop, the lower the effective per-trip cost becomes.
ORBIS reusable pallets are molded from engineering-grade resins, giving them consistent dimensions trip after trip. That consistency is particularly important in automated facilities, where variability in pallet height or deck flatness can interrupt conveyor flow and cause line stoppages.
The economic case for reusable pallets is built on total cost of ownership, not purchase price. Wood pallets carry a lower upfront cost but accumulate ongoing expenses: replacement after damage, disposal fees, and the labor involved in sorting and removing broken boards before they damage product or equipment.
Plastic pallets eliminate most of those recurring costs. Because they do not absorb moisture, they resist warping, cracking, and the mold growth that shortens wood pallet service life in temperature-controlled environments. Consistent construction means fewer pallets pulled from rotation for damage.
Key cost factors when comparing reusable plastic to single-use alternatives:
For a detailed breakdown of the plastic-versus-wood cost comparison, see the ORBIS guide: Plastic vs. Wood Pallets.
A reusable pallet only delivers its full economic and environmental value when it comes back. Returnable plastic pallets are most effective in closed-loop systems: controlled networks where pallets move between a defined set of facilities and are retrieved after each delivery.
Successful returnable pallet programs share a few common characteristics:
One of the most practical advantages of plastic pallet design is the ability to reduce return freight costs through nesting. Nestable plastic pallets are designed so that empty pallets fit inside one another, dramatically reducing the trailer space required for the return leg. Fewer return loads means lower freight cost and a smaller carbon footprint per cycle.
Stackable plastic pallets serve a similar function in operations where vertical stacking of empties is preferred over nesting. Both configurations are standard across the ORBIS product line and can be selected based on the return logistics of a specific program.
ORBIS manufactures reusable plastic pallets across five primary categories, plus load-securing accessories. Each is designed for specific handling, storage, and return-transport requirements.
Nestable pallets are built for moving, storing, and distributing product loads within a warehouse, distribution center, or across the supply chain. Empty pallets nest together at ratios up to 4:1, reducing the trailer space and freight cost required for the return leg. Contoured surfaces, dimensional consistency, and the absence of nails or splinters make them a direct replacement for wood in high-speed automation and conveyor environments.
Rackable plastic pallets are designed for unsupported racking systems where floor space optimization is a priority. They reduce product damage associated with wood pallets and skids, are highly cleanable, and are available in FDA-approved and fire retardant materials. Selected models carry Factory Mutual approval for fire ratings equivalent to wood pallets.
Stackable pallets are suited to processing, manufacturing, and distribution operations, including food and beverage, pharmaceutical, and automated handling environments. They handle static loads up to 30,000 lbs and resist splintering, warping, and cracking, and are non-porous for easy cleaning. Dimensionally consistent construction and consistent tare weights support palletizers, depalletizers, automatic strapping equipment, and high-speed automation systems.
Top caps and top frames secure pallet loads across automotive, food, beverage, and pharmaceutical applications. They maintain uniform weight distribution, improve load integrity, and can eliminate the need for banding, stretch wrapping, and the associated labor and machinery costs. Available in injection molded, structural foam, and single sheet thermoformed versions.
Layer pads and divider sheets protect product between load layers and combine with plastic pallets and top frames to create a complete, closed shipping system. Non-sloughing plastic construction eliminates the dust, fiber, and splinter contamination common with fiber or corrugated sheet alternatives. They are 100% recyclable, reusable across multiple shipments, and available in solid and corrugated styles with custom size, print, and color options.
For operations transitioning away from wood pallets or skids, ORBIS plastic pallets address the limitations that drive that decision.
Hygiene and contamination control. Wood absorbs moisture and harbors bacteria, making it a liability in food, beverage, pharmaceutical, and meat and poultry environments. Plastic pallets are non-porous, easy to wash, and do not support mold growth. FDA-compliant material options are available for direct-contact applications.
Dimensional consistency. Wood pallets vary in height, board thickness, and overall flatness. That variability creates problems for automated conveyor and sortation systems. ORBIS plastic pallets are molded to precise tolerances, providing the consistent interface that automated handling equipment requires.
Elimination of fastener hazards. Protruding nails, staples, and splinters from damaged wood pallets cause product damage, packaging tears, and worker injuries. Plastic construction eliminates those hazards entirely.
Fire rating options. Where facility fire codes or customer requirements call for fire-rated materials, ORBIS offers plastic pallet options engineered to meet those specifications.
For a full comparison of plastic and wood pallet performance across these dimensions, see Plastic vs. Wood Pallets.
When an ORBIS plastic pallet reaches the end of its service life, the material does not go to landfill. The resins used in ORBIS pallet construction are recyclable, and ORBIS operates a take-back program to support end-of-life recovery.
Through Recycle with ORBIS, retired pallets and other plastic packaging are collected and directed into recycling streams. This closes the material loop: product that was manufactured from resin returns to resin at the end of its useful life, reducing the volume of plastic that enters the waste stream.
For operations with sustainability reporting requirements or circular economy commitments, end-of-life recovery through a structured program provides documentation of responsible material disposition — not just a claim.
ORBIS is a U.S.-based reusable plastic pallet manufacturer and plastic pallet company with the broadest product selection in the industry. Whether you are designing a new returnable program, replacing wood pallets across an existing network, or sourcing a specific footprint for an automated facility, ORBIS serves as a plastic pallet supplier with standard and custom options to match your application.
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