In logistics, the pallet is a fundamental asset that directly determines cargo safety and operational efficiency. For non-standard, heavyweight goods, a pallet’s performance becomes the ultimate test of a manufacturer’s technical prowess and the capabilities of their plastic pallet making machine.

ThoYu recently rose to this challenge by custom-designing and manufacturing a heavy-duty plastic pallet for a client in Tobago. This pallet, engineered for transporting massive machinery components, has set a new industry benchmark with an exceptional dynamic load capacity of 2.5 tons and a static load capacity of 10 tons.

When Standard Pallets Are Not Enough

The client’s raw material was HDPE (High-Density Polyethylene), a common and excellent choice for plastic pallet production due to its superior toughness and strength.

In the industry, a standard 1000mm x 1200mm plastic pallet typically offers a dynamic load of 1.5 tons and a static load of 4-6 tons, which is sufficient for general logistics.

However, our Tobago client needed to transport heavy machinery parts—high-value cargo with immense weight. Standard pallet capabilities fell far short of their requirements.

“We need pallets that can truly shoulder heavyweight goods. The data must far exceed ordinary standards!” the client insisted, demanding rigorous load testing.

Precision Engineering Through Advanced Manufacturing

Faced with this heavyweight challenge,ThoYu’s technical team leveraged our 15 years of expertise and state-of-the-art plastic pallet making machines to deliver a solution with two core upgrades.

1. Structural Optimization & Precision Molding

Our team conducted professional mechanical analysis to completely redesign the pallet’s structure. This was precisely translated into a physical product through our high-precision plastic pallet making machines.

Thickened Load Deck: Enhanced overall rigidity.

Reinforced Ribs: Widened and thickened critical support ribs to create a high-strength skeleton.

Optimized Base Design: Redesigned the feet and underside structure to scientifically distribute stress and load evenly.

2. Strategic Weight Increase

Every extra kilogram was strategically added to directly boost load-bearing capacity. While a standard pallet of this size weighs around 18kg, our custom solution weighs 26kg. This is not simple “over-engineering” but a calculated enhancement, ensured by the consistent quality output of our plastic pallet production equipment.

( heavy-duty pallet from multiple angles)

 Rigorous Testing: Proving Unmatched Performance

The true test of any design and manufacturing process is performance. Our pallets passed with flying colors.

Dynamic Load Test (2.5 Tons): Carrying 2.5 tons, the pallet remained stable and secure throughout forklift movement, including travel and turning, without any sway or deformation.

Static Load Test (10 Tons): Even under the immense pressure of a 9-ton load, the pallet surface remained perfectly flat, and the structure was as solid as a rock. Subsequent testing confirmed a maximum static load capacity of up to 10 tons, setting a new record for pallets of this specification.

( Static load test with weights stacked high)

A Transparent Partnership: Showcasing Our Production Power

Confident in our process, theThoYu team invited the client for a “fully transparent” factory tour. We opened our doors to everything—from raw material inspection and the operation of our plastic pallet making machines to quality control and final packaging.

“This is the first time we’ve seen such a meticulous and transparent production process!” the client remarked. Our professional loading procedures and detailed technical answers further solidified their trust: “The attention to detail shows your professionalism.ThoYu is truly reliable!”

Ready to Elevate Your Logistics with Custom Plastic Pallets?

Contract us now，from factory tours and material testing to product customization and production line consulting, our expert team is online to provide you with a satisfactory solution!