When your supply chain relies on pallets that travel once—and the return journey isn’t part of the plan, the right pallet choice matters. One-way shipping presents unique challenges: cost of freight (including return/empty cost), space efficiency, weight impact on transport, regulatory/export requirements, and simplicity of handling. Plastic pallets often provide an excellent solution for these demands.
Prioritize Lightweight & Cost-Effective Construction
One-way pallets don’t need to survive hundreds of cycles, so cost and weight become top priorities. Lightweight plastic pallets reduce empty return freight and cut transportation fuel or freight-cost burdens. Many manufacturers classify “one-way use” plastic pallets specifically for export or domestic shipments where pallet recovery is improbable.
For example:
- A pallet constructed of recycled composite materials, or a lighter-duty plastic pallet can hit the cost-target for one-way usage.
- Nestable designs help further reduce space for empty pallets, lowering empty freight cost back.
Choose a Pallet Style Suited to the Shipping Scenario
There are two primary plastic pallet styles that work well for one-way shipping: nestable and stackable/non-rackable lightweight pallets.
- Nestable pallets: Designed to nest into one another when empty, meaning you can return many more units in the same space. This greatly reduces return freight costs.
- Non-rackable or “one-way use” pallets: These are simpler, lower-cost pallets built for shipping and not necessarily for long-term warehouse racking or heavy reuse. Such palettes are often recommended when load cycles are minimal.
Depending on your operation (export vs. domestic, pallet return vs. no return, empty-pallet shipping cost), you’ll pick accordingly.
Material and Build Considerations
For one-way shipping, material and build still matter—but the premium features needed for long-cycle reuse may be scaled back. Key considerations include:
- Resin type: A lower-cost resin blend or recycled plastic may be acceptable for one-way usage since durability is less of a concern.
- Deck type: A solid deck or vented deck depending on what you’re shipping. For export or container loads, you may need decking that supports strapping or secure freight.
- Fork access and footprint: Standard footprint (48” × 40” is common) and 4-way fork entry helps maximize loading flexibility.
- Regulatory/export compliance: If pallets are used for international shipping, weight, size, and pest/exposure regulations might apply—plastic pallets often avoid certain ISPM-15 treatments required of wood.
Maximize Freight Efficiency
One of the main cost drivers for one-way shipping is the return of empty pallets (if that is even intended), or the wasted space if pallets cannot nest or stack efficiently. To optimize:
- Use nestable pallets or pallets that collapse/stack when empty to reduce return volume.
- Choose pallets designed to maximize container/truck utilization (weight vs payload, footprint alignment).
- Evaluate whether the empty pallet return is even feasible. Sometimes the best decision is a true one-way pallet—ship, deliver, and leave it behind.
Balance Cost, Performance & Sustainability
Even though one-way pallets are cost-sensitive, you still need to protect the shipment. Poor pallet performance can cost more via product damage or freight delays than you saved in pallet cost. Consider:
- Load capacity: Make sure the pallet can handle the dynamic load during transport.
- Impact and environmental conditions: Export containers, truck transport, exposure to weather may challenge cheap pallets.
- Sustainability/ waste: Even one-way pallets contribute waste or disposal cost. Some plastic one-way pallets may be recyclable at end-of-life, supporting sustainability goals.
When you’re heading into a one-way shipping scenario, the right plastic pallet is one that marries low cost, lightweight design, shipping-friendly features (nestable or stackable when empty), and adequate performance for the journey. By matching the pallet spec to the freight, transport mode, and return logistics (or non-return scenario), you protect your bottom line and your supply chain.
If you’re evaluating plastic pallets for one-way shipment, whether domestic or export, and want help picking the right specs, call 877-651-7816 to talk to a Plastic Pallet Pro today.
