7 simple ways to prevent plastic pallet damage.

Plastic pallets are a popular choice for shipping and storage due to their durability, lightweight nature, and recyclability. However, even though plastic pallets are known for their resilience, they are not invincible. 

What are the common mistakes that can lead to plastic pallet damage and how to prevent them from happening?

In this guide, we will explore these common mistakes and provide practical tips on how to prevent them, ultimately ensuring the optimal performance and lifespan of your plastic pallets.

Common Mistake That Cause Damage To Plastic Pallet :-

1. Forklift Handling:-

Incorrect use of the forklift, such as turning before clearing the pallet, improper positioning and alignment of the forks during loading or off-loading, and incorrect fork distance setting, can lead to potential damage, instability, and risk of items falling off the pallet.

How to resolve:- 

To correct these mistakes, ensure the forklift forks are completely clear of the pallet before turning, maintain horizontal fork positioning during loading or off-loading, and set the fork distance at around 60% of the pallet width for optimal stability and safety.

2. Mishandling of Plastic Pallet:-

Rough handling during loading, unloading, and transportation can result in cracks, fractures, or other forms of damage to plastic pallets. Stacking pallets improperly, Dragging or dropping pallets especially from significant heights, can result in cracks, deformations, or weakened structural integrity. Improper handling of plastic pallets can also cause damage. 

How to resolve:- 

To mitigate this risk, provide adequate training to workers on proper lifting and carrying techniques. Emphasize the importance of lifting pallets correctly using appropriate equipment such as forklifts or pallet jacks, and ensure that pallets are stored and transported in a manner that minimizes potential impacts. Additionally, establish clear guidelines for stacking and securing pallets to prevent them from shifting or falling during transit. 

3. Proper Elevation for Plastic Pallet:- 

Carrying plastic pallets too low to the ground can cause them to catch on uneven surfaces, ramps, or bumps, potentially resulting in damage due to contact with the ground. This contact can cause the pallets to become damaged or even dislodged from the forklift, posing a safety hazard to both the operator and anyone nearby.

How to resolve:- 

To correct this mistake, ensure that the plastic pallet is lifted to an appropriate height with the help of a hand pallet truck or any other pallet lifter and movement equipment, above the ground during transportation or movement to prevent contact with uneven surfaces, ramps, or bumps, thus reducing the risk of damage.

4. Exposure to Harsh Environments:- 

Exposure to harsh environmental conditions such as extreme temperatures, UV radiation, or chemical exposure can accelerate the degradation of plastic pallets. Prolonged exposure to sunlight can cause plastic pallets to become brittle and prone to cracking, while exposure to certain chemicals can cause corrosion or weakening of the material. 

How to resolve:- 

To mitigate the effects of harsh environments, store plastic pallets in a covered or shaded area away from direct sunlight, and avoid exposing them to corrosive substances whenever possible. When transporting goods in cold storage facilities or hot climates, opt for pallets specifically designed to withstand such conditions.

5. Overloading:-

Improper assessment of the static and dynamic loads of plastic pallets can lead to damage during transportation, risking the integrity of both the pallets and their contents. Neglecting to consider these factors may result in pallet failure, causing disruptions and potential losses in the supply chain. 

How to resolve:- 

To rectify these mistakes, it’s crucial to accurately determine the maximum static load for stacking pallets and ensure proper distribution of weight to prevent damage. Additionally, assessing the dynamic load during transit and evenly spreading the weight on the pallets can mitigate risks and maintain the integrity of the goods being transported.

6. Inadequate Storage for Plastic Pallet:- 

Improper storage practices can also lead to plastic pallet damage. Stacking pallets haphazardly or placing heavy objects on top of them can cause deformation or crushing, compromising their structural integrity. 

How to resolve:- 

To ensure safe storage, stack pallets evenly and securely, avoiding excessive weight or uneven distribution. Consider using pallet racking systems or pallet stacking frames to maximize space utilization while minimizing the risk of damage.

7. Inadequate Maintenance:-

Neglecting to properly maintain plastic pallets can also contribute to their premature deterioration and reduce their lifespan. 

How to resolve:- 

Implement a proactive maintenance schedule that includes routine inspections for signs of damage or wear, such as cracks, chips, or loose components. Repair or replace damaged pallets promptly to prevent further degradation and ensure the safety of goods in transit.


Plastic pallets are a versatile and durable solution for shipping and storage needs, but they require proper care and attention to maintain their effectiveness over time. By avoiding common mistakes you can prolong the lifespan of your plastic pallets and maximize their value. 

By following the preventive measures outlined in this guide, you can ensure that your plastic pallets remain in optimal condition, saving you time, money, and resources in the long run. 

Swift Technoplast is your trusted partner in the plastic pallet industry. With our extensive experience and high-quality products, we can help you find the perfect solution tailored to your specific needs.

Visit our website and grab the best deal in the market.

About swift-technoplast