Pallets are used throughout the world to move and store materials. Food plants would have a tough time functioning without them; yet, many plants seem to take the lowly pallet for granted and have not bothered to develop, document, and implement a pallet management program. A program for pallet management should consist of the following elements:

• Pallet specifications
• Pallet storage
• Pallet inspection
• Pallet use within and outside of the plant
• Pallet maintenance
• Shipping requirements
• Pallet cleaning. 

One of the reasons that some food processors are switching to plastic pallets is that they can be washed, whereas wood cannot. Another reason is that some operations simply do not want wood on the processing floor.

The National Wooden Pallet & Container Association¹ is a good reference for helping establish pallet specifications. The pallet most used throughout the food industry is a wooden pallet sized 40 × 48 inches, but they do come in many other sizes. If a processor is packing products that will be shipped overseas or buying products from overseas, then the specifications must mandate that the pallets used to transport the materials should be heat treated to ensure they are not infested. Heat treatment will kill boring insects, larvae, and their eggs. 

The company should also establish specifications for both new and used pallets. Both sets of specifications should include language stating that the pallets must be in good condition, undamaged, clean, and free of pests. In addition, processors should mandate that used pallets were not employed to ship trash, waste, or chemicals; nor should they accept pallets that may have been soiled with animal byproducts or waste. 

Pallet Storage Basics

A proper pallet storage protocol should encompass the following elements:

1. All pallets shall be stored in defined areas. Areas will be provided for storing pallets that are employed in production and any pallets that are damaged. 
2. The pallet storage area shall be marked with signage and clearly delineated with white lines on the floor.
3. The pallets shall be stored in the designated area at least 18 inches off the ground, on solid iron bars or concrete blocks. The storage area shall be designed to ensure that pallets are not flush to the wall and that an 18-inch inspection aisle is maintained.
4. The pallets shall be stored so that they can be easily accessed and moved using a forklift.
5. Pallets shall be stored under cover, so they are not exposed to rain or pests. Pallets shall not be stored outside or on the ground.
6. Pallets must be shrouded when not in use to protect them from dirt, pests, and cross-contamination.

Why mandate that pallets be stored at least 18 inches off the ground? Many processors store pallets on the ground, which exposes them to standing water or other contaminants. Wooden pallets absorb water, which may be contaminated by microorganisms of public health significance such as Salmonella or Listeria. The odds of this happening increase in facilities that process and handle meats or raw agricultural commodities. Independent laboratory studies have demonstrated that pathogens and other indicator organisms may be isolated by soaking pallets in sterile water or culturing wood shavings from those pallets in the same medium. These studies demonstrate that past uses of the pallets are clearly related to the microflora recovered. 

Processors should establish the same requirements for pallets that are used for shipping containers—clean, no infestations, no off-odors, and used for food only. Along the same lines, if customers demand product on clean pallets that are in good condition, then there is no reason to accept inbound shipments on damaged or dirty pallets.

Best Practices for Pallet Inspection 

Whenever pallets are to be used in production, they should be inspected prior to use. This is especially important if they were previously stored outside. Pallets must be individually inspected before being brought into the warehouse or production area. Many users have equipped the inspection area with compressed air hoses that allow the operator to blow off the pallets with high-pressure air before they are used. High-pressure air will remove pests and dirt. 

The inspection step must also be used to ensure that the pallets are in good condition. Wooden pallets that are splintered or have broken boards or loose nails should be set aside for repair, recycling, or disposal. Damaged or splintered plastic pallets should also be set aside. Wooden pallets can be fixed in-house or by a pallet supplier, while broken plastic pallets are generally non-salvageable and must be set aside for recycling. 

Damaged pallets and those that are rejected should be stored in a designated area that is clearly marked, as mentioned earlier. Pallets that are accepted for use shall be transferred to the designated holding area. Wood or plastic pallets that are badly stained or exhibit off-odors must also be set aside; however, dirty plastic pallets may be washed. Some processors have installed a pallet washer that allows for regular cleaning and sanitizing of plastic pallets. 

Some processors utilize both wooden and plastic pallets. Their general rule for these operations is that anything moving into the production area—whether ingredients, raw materials, packaging, or work-in-progress—be moved on a plastic pallet. This may involve transferring the materials in the warehouse or a staging area; regardless, the pallet with materials that are moving into production can be cleaned and sanitized. Using this process, the plant also minimizes potential contamination from wood and metal (e.g., nails or staples) into the production area. Some audit schemes will downgrade a facility for having wood in a processing area, so this type of program can protect a processor in several ways.

Why Establish a Pallet Management Program?

It is essential that food processors establish a properly documented pallet management program. The work instructions or procedures should clearly define who is responsible and clearly outline procedures and expectations. Finally, all workers involved with the program must be trained, and that training must be documented. 

Is the pallet management program in your operation documented? Examine what is being done, and if it is not documented, then get it in writing. Remember: it is impossible to train people properly and be sure that programs are being followed without having well-documented procedures. 

You may also want to conduct and document a risk assessment of your current pallet management program. This may help identify a small gap that could create a bigger problem in the future—and provide an optimal opportunity to fix it before something goes wrong.

Reference

1. National Wooden Pallet & Container Association. 2025. https://www.palletcentral.com/.