At Pallets of Texas, we build custom pallets for products that standard sizes were never meant to carry.
If your products are too long, too heavy, too tall, or shaped so they leave half the deck empty, stock pallets quietly drain money from your shipping budget through damaged goods, wasted trailer space, and pallets that fail before their second trip. Our company designs and builds pallets to your exact specifications in our Dallas facility, using Grade A materials and the same quality checks we run on every order, and we deliver finished pallets across the Dallas-Fort Worth Metroplex.
Pallets of Texas is a family-owned pallet manufacturer and a proud member of the National Wooden Pallet and Container Association. We build custom pallets in our own Dallas facility on West Ledbetter Drive, so the crew cutting lumber for your pallets and the account manager answering your calls work in the same building. There are no order minimums, which means a one-time run of custom pallets gets the same attention as a standing weekly production schedule.
Every order is built from Grade A wood unless you request Grade B. We inspect incoming materials for rot and insect damage, and our QA team checks the finished pallets for fastener quality before they leave the yard. We deliver on time on more than 99% of orders, and we offer delivery and pickup across Dallas County and the wider Metroplex. Finished orders are staged at our West Ledbetter Drive dock, and your account manager confirms the pickup window before your driver leaves, so nobody sits waiting on a forklift. We run our own trucks rather than handing your order to a broker, which is why the date we give you is the date we keep.
Standard pallets exist because most freight fits them. The 48x40 GMA footprint moves grocery, retail, and consumer products through nearly every warehouse in Texas, and when your products fit it, you should use it. Standard pallets cost less per unit, and warehouses accept these pallets everywhere.
Trouble starts when the products and the deck disagree. Overhang is the failure we see most. A crate running 52 inches long on a 48-inch deck rests its weight on unsupported corners, and the boards split at the first hard forklift stop. Underhang wastes space you paid for and lets cartons shift in transit. Loads that concentrate weight in one spot need stringers or blocks placed where that weight actually sits. Tall products need a wider footprint to stay upright on a truck.
If that sounds like your business, custom pallets cost you less over a year than replacing crushed products and broken standard pallets.
Every order follows the same pallet design process our team developed in-house, and that process starts with your products rather than a catalog number. We ask what the load weighs, how that weight is distributed, how high you stack it, whether it sits in racking or on the floor, how it is handled, and where it is shipping.
Those answers drive the pallet design, setting deck dimensions along with board thickness, board spacing, fastener pattern, and wood species. Spacing matters more than most buyers expect. If your products are small enough to drop between deckboards, tighter board spacing solves a damage problem no amount of stretch wrap will fix. Softwood keeps weight and price down, while hardwood adds durability for repeat trips and heavy point loads.
We then build sample pallets, you load them, and we refine the pallet design before production runs.
That step creates a design you can reorder by name, and every repeat run is made from the same approved drawing.
Custom-designed pallets are manufactured in two constructions, and the right pallet design depends on how your pallets get handled. Stringer pallets use three parallel boards running the length of the deck. They are lighter, cost less, and suit two-way forklift access or notched four-way entry.
Block pallets use nine solid blocks in place of stringers, creating true four-way access for forklifts and pallet jacks. Block pallets carry more weight, hold their shape through more trips, and are the better choice for racking and conveyor lines. If your pallets run through automated systems, tell us early, because automated systems reject pallets on tolerances a human operator would never notice. Most racked pallets in high-volume warehouses are block pallets for this reason. We build custom-designed pallets in both constructions, and our team will tell you which design your products actually need.
Custom pallets leaving the country must be heat treated to meet ISPM 15. The heat treatment process brings the wood core to a set temperature for a set time, eliminating insects and larvae and earning the stamp customs officers look for. Untreated wood packaging gets held, fumigated at your expense, or refused at the border. We build heat-treated custom pallets in any dimension we manufacture. Our heat-treated wooden pallets page covers the standard and its marking requirements in full.
We keep standard sizes moving in volume, including 48x40, 40x40, 44x44, 44x42, 48x48, 32x32, 52x40, 72x40, and 40x80. Beyond those, we cut pallets to whatever your products need. We regularly manufacture pallets at 36x36, 42x42, 47x32, 48x42, 58x41, 72x48, and 96x48, and our 96x48 pallets carry up to 7,000 pounds.
The dimensions below are the ones we manufacture most often, each with a published load capacity so you can match a pallet to your load before you order.
| Dimension (inches) | Load capacity (lbs) | Fork access | Pallet weight (lbs) |
|---|---|---|---|
| 36x36 | 3,500 | Two way | 30 |
| 40x40 | 2,500 | Two way | 38 |
| 42x42 | 4,000 | Two way | 40 |
| 47x32 | 5,000 | Two way | 32 |
| 48x40 | 2,500 | Four way | 40 |
| 48x42 | 3,000 | Four way | 42 |
| 48x48 | 3,500 | Two way | 50 |
| 58x41 | 2,000 | Four way | 60 |
| 72x48 | 7,000 | Four way | 75 |
| 96x48 | 7,000 | Four way | 100 |
Pallet weight shifts by a pound or two between new and heat-treated stock. Anything outside this list gets quoted from your drawing.
Odd dimensions are not an exception here. If your equipment ships at 61 inches wide, we create a 61-inch deck instead of billing you for overhang. Wooden pallets remain the most flexible packaging option for this reason, because a saw and a nail gun can reach a dimension an injection mold cannot. If you are unsure which dimension your load needs, call 972-885-7935, and we will work it out with you.
Custom pallets do more than protect one shipment. Sizing pallets to your rack bay, your trailer, and your case count is real warehouse optimization, and the savings compound.
A deck built to your racking removes wasted vertical and horizontal space, raising the pallet positions you get from the same square footage. Pallets manufactured to fit your trailer cleanly lift the units you ship per load, which lowers shipping cost per unit. Consistent pallet designs across your supply chain also cut handling time and improve safety, because crews stop improvising around whatever arrived on the last truck.
We buy back used pallets too, so the same supply chain receiving your custom pallets can return them for credit rather than paying to dispose of them. Across a full year, these custom solutions protect both your products and your margins, which is why our customers treat pallets as packaging rather than as a commodity.
We supply pallets to warehouses, distribution centers, manufacturers, and logistics businesses across the Metroplex. The industries that come to us for custom solutions usually share one trait, which is products a standard deck cannot hold safely.
Machinery and equipment industries need decks rated for concentrated point loads, and we have designed pallets for equipment that ships only a few times a year. Food and beverage operations need clean wood and predictable dimensions for cold storage handling. Agriculture and building products industries move long or awkward items that overhang everything stock. Across all of these industries, our services cover design, build, delivery, and buyback, so you are not stitching solutions together from three separate vendors. Whatever your sector, our pallet design is tailored to the specific needs of the products in front of us, and we stand behind the durability and reliability of every pallet we build.
Per unit, custom pallets cost more than a standard 48x40, because they use different quantities of wood and a dedicated setup. Across a year, the comparison usually flips, since pallets that fit stop product damage, cut replacement, and move more units per trailer. Contact us with your dimensions and volume, and we will quote both.
Lead time depends on volume and whether the pallet design is new or repeat. We quote a firm date alongside the price, and we meet our delivery windows on more than 99% of orders. One customer received custom-size pallets within 48 hours during an urgent run.
No. We hold no order minimums, which is why regional buyers work with our company instead of national suppliers. We build a single run of pallets or a recurring production schedule, and we create repeat pallet designs from your approved drawing.
Load weight, product dimensions, stack height, how the pallets are handled, whether they enter automated systems, and whether they are shipping internationally. If you are unsure, send photos of your current setup and our services team will work from those.
Yes. Send the drawing, the part number, or a sample pallet, and we will match the dimensions, construction, and fastener pattern to meet your exact needs, and we keep that drawing on file for every reorder.
