Custom plastic pallets: moulds, logos and batch sizes
In briefColour, hot-stamped logos, serial numbers and RFID can be added to a standard pallet without a new mould. You only need a dedicated mould when the shape or dimensions change, and then the moulding process decides the cost, the lead time and the minimum order quantity.
Before you talk about moulds for a custom plastic pallet, ask yourself what you want to change. If you only need to recognise your own pallets, a standard pallet can be customised without touching the mould. If your load will not fit a standard pallet, you need a new mould, and the cost moves to another scale.
No new mould: colour, logo, numbering, RFID
In closed loops these are the most requested options: they help you recognise pallets, get them back and track them.
| Customisation | What you get | What to know |
|---|---|---|
| Hot stamping | Logo, text or numbers pressed into the plastic | One colour, up to 200×200 mm in one manufacturer's offer [1] |
| Special colour | Pallets you can tell apart at a glance, separate departments | Available depending on quantity [2] |
| Serial numbering | Each pallet has its own number | Done by hot stamping [2] |
| RFID transponder | Automatic reading at a gate | Embedded in the plastic [3]; only on some models [2] |
| Label holder | Space for barcodes and documents | Available on some models [2] |
Hot stamping
A coloured foil is fused into the plastic at high temperature. According to one manufacturer's data sheet, the mark does not fade even with frequent high-temperature washing [1]. Prices are rarely published. As a rough guide, one-colour hot stamping costs about 3 to 7 euros per pallet, excl. VAT and shipping: a single pallet costs more, and over a few hundred pallets the price moves towards the bottom of the range.
Colour
The colourant is blended with the plastic in the moulding machine [4], so a non-catalogue colour needs a dedicated production run and a minimum quantity. One manufacturer, for example, states that special colours are available depending on quantity [2]. Ask for the exact figure in the quote.
RFID
The transponder can be embedded in the plastic, where it is protected from dirt and impact, and some manufacturers already offer this [3]. Which codes to write to it (GRAI, SSCC) and how to test reading are explained in the guide to RFID pallet tracking. If the pallet is going into an automated warehouse, see also the guide to pallets for automated warehouses.
When you need a new mould
You need a new mould when the shape changes: non-standard dimensions, loads that do not sit on a flat deck, pallets that have to fit into a machine.
Reels are a case in point. A reel on a flat pallet rolls and puts all its weight on a single line: to hold it still you need saddles or cradles shaped to the diameter. This is how ROLL works: its reel pallets are made by partner companies using moulds owned by ROLL and, according to company information, ROLL holds three granted patents [7]. The versions are described in the guide to reel pallets.
Six processes compared
In 2006 a US trade magazine described the six processes used to make plastic pallets [4]. The article is twenty years old and the machines have changed: use the table to find your way among the processes, not to estimate costs.
| Process | Mould | Cycle | Typical materials | Notes |
|---|---|---|---|---|
| High-pressure injection moulding | Very expensive | Fast | PP copolymer, HDPE | Fine detail, high pressures |
| Structural foam (low-pressure injection) | Cheaper than injection | Medium | PE or PP with nitrogen | Less material, good strength-to-weight ratio |
| Thermoforming (single or twin sheet) | Much cheaper | Slow | Polyethylene sheet | Light pallets; twin sheet is hollow |
| Compression moulding | Two-part mould | n/a | Many recycled materials, rubber too | Suits mixed materials |
| Rotational moulding | The cheapest | Slow | LLDPE, cross-linked PE | About 40 minutes per cycle on conventional machines |
| Profile extrusion | Die, not a mould | Continuous | Regrind, post-consumer | Profiles cut and assembled like timber |
Source for the whole table: [4]. 'n/a' means the article does not give the figure.
Twin sheet is hollow: if it is punctured and left out in the rain, it holds water [4]. Strength depends more on design and reinforcement than on the process: for materials, see the guide to plastic pallet materials.
Mould lead times and costs
We have not found reliable published prices for pallet moulds. The figures you find online come mostly from toolmakers' portals, with no details about the part. So we only give the orders of magnitude stated by one manufacturer.
A thermoforming manufacturer states that a twin-sheet mould costs up to 90% less than an injection, rotational or blow mould, and that it takes 6-10 weeks to develop, against 3-6 months or more for the others [5]. This is a commercial claim from a company that sells that process: use it to get a sense of scale, then ask for quotes.
The sum to do is the mould cost divided by the number of pallets you will produce. An expensive mould spread over many pallets adds little to each one; a cheap mould spread over a few adds a lot. On top of that comes the price per pallet, which falls with injection moulding because the cycle is fast [4].
Prototype, testing and sampling
A new pallet must be tested before series production. The reference tests are those in ISO 8611; Part 2, which covers performance requirements and test selection, was updated in 2025 [6]. Ask for results on the finished model, in the production material and colour: a different masterbatch or a share of recycled material changes how the pallet behaves. What to put in the specification and how to inspect batches is covered in the guide to specification and testing. How to read load capacities is explained in the guide to plastic pallet load capacity.
Who owns the mould
No standard helps you here: the contract decides. If you pay for a mould, put in writing:
- that the mould is yours, with an identification number;
- where it is kept and who insures it;
- who pays for maintenance and repairs;
- how you get it back if you change moulder, and how quickly.
Without these clauses the mould stays, in practice, with the moulder, and so does the ability to produce your pallet. This is how ROLL works: it owns the moulds and production is carried out by partner companies [7].
If you need a pallet for non-standard reels, write to us from the contact page. For a standard flat pallet with your logo, one of the plastic pallet manufacturers is the most direct contact.
Frequently asked questions
Can I have my logo on a standard plastic pallet?
Yes, with hot stamping: the logo is pressed into the plastic at high temperature in one colour and, according to one manufacturer, it withstands frequent high-temperature washing. No new mould is needed. As a rough guide, hot stamping costs about 3 to 7 euros per pallet, excl. VAT, and the price falls with quantity.
How many pallets do I need to order to get a custom pallet?
It depends on what you customise. Hot stamping can be done on just a few pallets. A special colour requires a minimum quantity that the manufacturer sets case by case. A new mould only makes sense if its cost, divided by the number of pallets you will produce, stays acceptable compared with a standard pallet.
How long does a custom-made pallet take?
The lead time depends mainly on the mould. According to one thermoforming manufacturer, a twin-sheet mould takes 6-10 weeks to develop, an injection or rotational mould 3-6 months or more. This is a commercial figure from one manufacturer: add time for the prototype, load tests and sampling.
Which process makes the strongest pallet?
No process always comes out on top. High-pressure injection moulding gives detailed parts and fast cycles, structural foam has a good strength-to-weight ratio, thermoforming gives light pallets. Strength comes from the design, the material and the reinforcement: ask for ISO 8611 test results on the finished model.
Can an RFID tag be built into a plastic pallet?
Yes. The transponder can be embedded in the plastic, where it is protected from dirt and impact, and some manufacturers already offer this. Others offer RFID only on certain models, so ask before you choose the pallet.
Who owns the mould for a custom-made pallet?
The contract decides. If you pay for the mould, put in writing that it is yours, where it is kept, who pays for maintenance and how you get it back if you change supplier. Without these clauses the mould stays, in practice, with the moulder, and so does the ability to produce your pallet.
Sources
- Transoplast: Company logo print, hot stamp (service data sheet)
- WERIT: ESD pallets (customisation, special colours, RFID, FAQ)
- Materialfluss: Personalized load carriers from Cabka-IPS with RFID transponders
- Pallet Enterprise: Six Processes Used to Make Plastic Pallets (2006)
- Universal Plastics: What is twin sheet thermoforming (commercial page)
- ISO 8611-2:2021, withdrawn on 20/02/2025 and replaced by ISO 8611-2:2025
- ROLL Packaging, about us (own moulds, partner companies, patents)
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