Packaging & Crating
Replacing Stock Pallets to Cut Damage on a Fragile-Component Shipment
A manufacturer shipping an irregularly shaped component was seeing damage on stock pallets that left dead space around the part. A custom plywood pallet, sized to the product, addressed it.
The Challenge
The customer's component didn't match a standard pallet footprint, which meant it shifted in transit and arrived damaged often enough to be a recurring cost — both in replaced product and in customer complaints downstream.
Our Approach
We measured the actual component and built a custom plywood pallet sized to its footprint, eliminating the dead space a stock pallet had left around it. Because the shipment ran on a recurring lane, we built the pallets as a reusable design rather than a single-use one.
The Result
The custom fit reduced shifting in transit, and the reusable design meant the pallet cost amortized across repeated shipments on the same lane rather than being rebuilt each time.
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