Custom Pallets
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A custom pallet is a wood pallet built to a specific size, weight rating, and handling profile rather than a stock dimension. Troymill engineers custom pallets up to 48 feet long and 100 inches wide, modeling every build in the Pallet Design System before production so the pallet performs on the first load.
Purpose-Built Platforms Tailored for Your Products
Standard 48 × 40s can’t solve every load-out problem. That’s why Troymill runs a dedicated custom-pallet line: to match exact dimensions, weight limits, and handling quirks so your freight moves safely from plant floor to final destination.
On our 50-acre Ohio campus, we mill stringers and deck boards in-house, drop every spec into Pallet Design System (PDS) software, and validate load ratings before the first nail sets. Whether you need an extra-wide deck for a CNC machine or a heavy-duty block pallet that slides through stretch wrap, the build is engineered first, then produced quickly.
From Drawing to Dock in Four Simple Steps
- Consult & Capture Specs – Send load size, weight, racking constraints, and shipping lanes.
- PDS Modeling – We simulate bending, shear, and forklift impacts to confirm safe working loads.
- Prototype & Approval – Sample pallets ship for trial fits and testing, adjustments made if needed.
- Full Production & Delivery – High-speed Viking nailers or hand-build tables take the design live; our sky-blue trailers roll it straight to your dock.
Custom Pallet Design Options and Enhancements
Category | Options Available | Why It Matters |
Deck & Stringer Thickness | 5/8″–2″ boards, 1¼″–2″ stringers | Dial in strength without excess weight. |
Entry Style | 2-way, 4-way stringer, full block | Match forklifts, pallet jacks, and conveyors. |
Fasteners | Helical nails, screw-shank, clinch plates | Prevent board pull-through on repeat cycles. |
Surface Features | Lead-edge chamfers, anti-slide cleats, edge caps. , holes, slots | Protect product surfaces, speed handling, allow for product fastening. |
Strap & Band Protection | Length-wise grooves, cross-notches | Recessed straps reduce crushed edges. |
ISPM 15 Treatment (on request) | Heat-treated, stamped, digital certificate | Export anywhere without pressure-treated wood. |
Custom Pallet Materials on Hand
- Southern Yellow Pine (SYP) – High strength-to-weight; perfect for industrial skids.
- Spruce-Pine-Fir (SPF) – Lighter loads, export crates, high-volume programs.
- Mixed Hardwood – Oak, maple, hickory blend for maximum durability.
Industries We Serve
- Heavy machinery & equipment OEMs
- Aerospace & defense tooling suppliers
- Automotive stamping & assembly plants
- Coil & pipe distributors
- Renewable energy (wind, solar component) shippers
- Food & beverage processors with unique rack footprints
Why Troymill for Custom Pallets?
- Scale & Speed – Prototypes within one week, production within two weeks, thousands per month if you need them.
- Engineering Confidence – Every pallet is backed by PDS load data One-Truck Solution – Mix custom pallets with standard sizes, recycled alternatives, or dunnage in the same delivery.
- Sustainability Commitment – Residual lumber recycled ; repaired pallets re-enter circulation.
Frequently Asked Questions
Up to 48 ft long by 100 in wide. Heavier or longer requirements can be reviewed on a case-by-case basis.
Absolutely. Basic length, width, height, and weight provide us with enough information to model an initial design and determine a price.
Our heat-treat kilns log time and core temperature for each batch; digital IPPC certificates accompany the BOL.
We nest, stack, or flat-pack designs wherever possible to maximize trailer utilization and cut freight costs.
A custom pallet is a wood pallet built to a specific size, weight rating, and handling profile, rather than a stock dimension, engineered for loads that a standard 48" x 40" pallet cannot carry safely.
Standard custom pallet production is typically about 10 business days after approval, with expedited builds available in about 5 business days when capacity and materials allow. Prototype timing depends on design complexity.
Southern Yellow Pine for strength-to-weight, Spruce-Pine-Fir for lighter loads, and mixed hardwoods such as oak, maple, and hickory for durability, combined in one pallet when needed to balance cost and load rating.
Yes. Send a sample, drawing, or the load and racking details, and we will model and reproduce the spec, then hold consistent dimensions and materials across every truckload.
Yes. Troymill pairs non-standard sizes with high volume, producing thousands per month and reserving capacity for recurring program lanes.
Two-way, partial four-way stringer, and full block four-way entry, matched to your forklifts, pallet jacks, and conveyors.
Let’s Build a Pallet That Fits Your Product—Not the Other Way Around
Share your load dimensions, handling challenges, and timelines. We’ll engineer, prototype, and deliver a custom pallet that meets every requirement, including strength, compliance, and budget.
Pride in Everything
Troymill pride means integrity, hard work and exceptional service each and every day, for each and every customer.
Above all else is our concern for quality and care taken in everything we do. Every member of the Troymill team, from management and foremen to our Amish craftsmen, takes their performance to heart and seeks new ways to better serve our customers.
Only by taking immense pride in every aspect of our work can we build and maintain strong, long-lasting relationships with our customers, suppliers, and employees.
