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Ever paid to ship water? That’s what happens when wood pallets soak up moisture and gain a few extra kilos. In logistics, every unnecessary kilogram eats into your freight budget. Plastic pallets stay consistent in weight, wood doesn’t—and that difference shows up in freight bills, container loads, and worker safety. This guide compares plastic vs wood pallet weight head-to-head and explains how those differences impact real logistics performance.
- How Much Does a 40 x 48 Standard Pallet Weigh
- How Much Does a Wood Pallet Weigh?
- How Much Does a Plastic Pallet Weigh?
- Plastic vs Wood Pallet Weight: Which One Works Better?
- Why Pallet Weight Matters in Logistics
- Frequently Asked Questions About Pallet Weight
- Conclusion: Choosing the Right Pallet for Your Needs
How Much Does a 40 x 48 Standard Pallet Weigh
The 40 × 48 inch pallet—better known as the GMA pallet—is the most common size in North America. But its weight isn’t a single fixed number. Why? Because two things make a big difference:
- Pallet design – stringer or block, nestable or rackable, full-perimeter or 9-leg.
- Pallet material – wood, plastic, or metal, each with its own density.
In practice, a wood GMA pallet usually weighs 35–70 lbs. A metal pallet of this size is around 50–51 lbs. And a plastic pallet in the same size comes in lighter, about 15–30 lbs.
How Much Does a Wood Pallet Weigh?
The weight of a wood pallet is rarely consistent. It shifts with the wood type, the pallet design, and even the thickness of each board. And since most buyers ask about the standard 40 × 48 in GMA pallet, the ranges below are based on that size:
- Softwood stringer pallets – usually 15–20 kg (33–44 lbs). They’re lighter and common for one-way transport.
- Hardwood block pallets – typically 25–30+ kg (55–66 lbs), and in some cases up to 50 kg (110 lbs). Stronger, but much heavier.
- Stringer vs. block – stringer pallets rely on parallel stringers and weigh less, while block pallets use solid blocks that add both durability and weight.
- Board thickness – thicker or denser hardwood boards can add several kilograms compared to thinner cuts.
If you’re wondering about other sizes, here are the weight ranges for some of the most popular wood pallet specifications worldwide.
| Pallet Size (in) | Pallet Size (mm) | Pallet Weight (kg / lbs) | Common Region / Country |
|---|---|---|---|
| 39.4 × 47.2 | 1000 × 1200 | 20–30 kg (44–66 lbs) | Europe / International (ISO standard) |
| 31.5 × 47.2 | 800 × 1200 | 18–25 kg (40–55 lbs) | Europe (Euro pallet / EPAL) |
| 42 × 42 | 1067 × 1067 | 18–28 kg (40–62 lbs) | Asia (Japan, South Korea) |
| 44 × 44 | 1118 × 1118 | 20–30 kg (44–66 lbs) | Australia |
| 36 × 36 | 914 × 914 | 12–20 kg (26–44 lbs) | Beverage industry (North America) |
| 42 × 48 | 1067 × 1219 | 20–30 kg (44–66 lbs) | North America / International (export use) |
Because wood is porous, weight also changes with the environment. Even after treatment, a pallet can gain or lose 2–3 kg (≈5–7 lbs) depending on whether it’s stored in dry or humid conditions.
But Plastic pallets don’t absorb moisture, so their weight stays the same. That stability is a key reason many buyers now prefer plastic over wood.
How Much Does a Plastic Pallet Weigh?
The weight of a plastic pallet stays stable—it does not change with humidity or storage conditions. What really sets the numbers apart is the design structure. The data below is from our 48 × 40 in (1219 × 1016 mm) plastic pallets, and actual weights may vary by design across different manufacturers.
- 9-leg nestable pallets – 9–14 kg (20–31 lbs). Lightweight, space-saving, and often chosen for export or air freight.
- 3-runner rackable pallets – 13–17 kg (29–37 lbs). Built for warehouse racking, reliable for medium to heavy loads.
- Full-perimeter (6-runner) heavy-duty pallets – 17–23 kg (37–51 lbs). Designed for industrial storage, cold chain, and automation systems.
- Double-sided pallets – 20–25 kg (44–55 lbs). Stronger and heavier, widely used in pooling and high-turnover operations.
Plastic pallets are more stable in weight because they’re made from HDPE or PP. For racking, many buyers add galvanized steel tubes. We suggest at least four tubes, which add about 4.8 kg (≈10 lbs) per pallet.
Below is a weight reference form our Enligntening Pallet plastic pallets. These ranges cover nestable, rackable, full-perimeter, and double-sided designs.
| Pallet Size (in) | Pallet Size (mm) | Plastic Pallet Weight (kg / lbs) | Aplicaciones Típicas |
|---|---|---|---|
| 31.5 × 47.2 | 800 × 1200 | 5.8–20 kg (13–44 lbs) | Euro standard exports, retail distribution |
| 39.4 × 47.2 | 1000 × 1200 | 13–22 kg (29–49 lbs) | ISO export loads, automation systems |
| 42 × 42 | 1067 × 1067 | 13–20 kg (29–44 lbs) | Paint and telecommunications |
| 43.3 × 43.3 | 1100 × 1100 | 12–22 kg (26–48 lbs) | Widely used in Asia, particularly Japan |
| 1165 × 1165 | (no inch equivalent, AUS standard) | 11–29 kg (24–64 lbs) | Australia, pooling and warehouse use |
| 42 × 48 | 1067 × 1219 | 14–23 kg (31–51 lbs) | North America, pooling and racking |
Like wood pallets, plastic versions work in export, warehousing, and automation. But there’s a key difference: plastic pallets don’t come with a fixed trip limit. For heavy-duty, long-term use, they deliver a clear advantage over wood.
Plastic vs Wood Pallet Weight: Which One Works Better?
We’ve already looked at the weight ranges of plastic and wood pallets; now let’s see how that plays out in real applications. Plastic does cost more upfront, but lighter weight lowers freight and longer service life means fewer replacements—making it the smarter long-term choice. The chart below uses the standard 48 × 40 in pallet to show weight differences across export, racking, and heavy-duty uses:
| Pallet Type | Plastic (kg / lbs) | Wood (kg / lbs) | Key Difference |
|---|---|---|---|
| Export use (one-way) | 5–10 kg (11–22 lbs), static load 1.5–2T | 15–20 kg (33–44 lbs), static load 1.5–2T | Plastic is ~50% lighter, cuts freight cost |
| Racking use | 13–25 kg (29–55 lbs), static load up to 6T | 18–25 kg (40–55 lbs), static load 4–5T | Plastic lighter, stronger in racking systems |
| Heavy-duty use | 19–43 kg (42–95 lbs), static load up to 6T+ | 25–50 kg (55–110 lbs), static load 4–6T | Plastic covers wider range, remains consistent |
In summary, plastic pallets provide more predictable weight, reduce freight overhead, and perform reliably across different applications. Wood pallets still serve one-way low-cost needs, but for long-term use and high-load operations, plastic clearly works better. Next, let’s look at why pallet weight itself has such a big impact on logistics performance.
Why Pallet Weight Matters in Logistics
We’ve seen that plastic pallets stay consistent in weight while wood varies. This difference directly shapes logistics performance in three key ways:
- Freight cost savings (air & ocean) – Every kilogram matters. Lighter pallets mean you ship more goods instead of paying to move excess pallet weight.
- Loading capacity per container – When pallet weight is predictable, container space is used more efficiently, reducing the risk of overload or wasted capacity.
- Worker handling & safety – Lighter, uniform pallets are easier to move and reduce strain, lowering the chance of accidents in warehouses and during last-mile delivery.
In Summary, plastic saves freight weight and ensures consistency; wood varies widely. Thanks to standardized raw materials and precision molding, plastic pallets keep a stable, predictable weight, while wood pallets fluctuate due to natural density differences and moisture changes. For export and long-haul shipping, plastic pallets help maintain logistics costs more effectively.
Frequently Asked Questions About Pallet Weight
1. Does adding steel tubes increase the weight significantly?
Yes, but it’s predictable. Four galvanized tubes add about 4.8 kg (≈10 lbs)—roughly a 20–30% gain on a 15–20 kg pallet. The extra weight directly improves rack safety and durability, and we suggest tubes only when heavy loads demand them.
2. Can I customize pallet weight for automated equipment compatibility?
Yes. Some automation systems have strict weight tolerances to ensure seamless processing. Manufacturer like Enlightening Pallet can adjust wall thickness, material density, or reinforcement configuration to meet your weight specifications without compromising structural integrity.
3. Is there a legal limit for pallet weight in export shipments?
Not directly—There isn’t a single global “pallet weight law,” but transport rules set the limits. For example, a 20-ft ocean container is capped at about 28 tons, and most air freight carriers restrict pallets to 1,000 kg or less. This is why accurate pallet weight is critical: even small mismatches can cause customs checks, fines, or extra charges.
4. What is the maximum weight a plastic pallet can handle?
Depends on the material. A 48 × 40 in wood pallet usually holds 1–1.5 t dyn, 3–4 t stat, 0.8–1.2 t rack. A plastic pallet supports about 1.5–2 t dyn, 6 t stat, 1 t rack, with higher rack loads when reinforced with steel tubes. Metal pallets go further, often reaching 2–3 t dyn, 5–6 t stat, 1.5–2 t rack.
5. Can lighter pallets actually reduce your costs?
Often they can. A lighter pallet means lower freight weight and easier handling, which cuts costs in shipping and labor. But lighter also can mean less durable, especially with wood pallets used repeatedly. Plastic is the exception: some models are lighter yet engineered to carry loads comparable to heavier wood or even metal designs.
6. Are heavier pallets stronger?
Not always. A pallet’s strength depends more on its design and material than its weight alone. For example, a 14 kg rackable plastic pallet with steel reinforcements can safely hold over 1,000 kg on racking, while a heavier wood pallet of 20–25 kg may flex or fail under the same load. Weight adds some stability, but smart engineering delivers true strength.
7. How heavy is a pallet of beer?
It depends on beer pallet dimensions, but on a common 48 × 40 in pallet, about 100 cases come to 1,200–2,000 lbs (≈550–900 kg) including the pallet. Weight varies with bottles vs. cans and stack height. Choosing lighter plastic pallets helps breweries cut freight costs compared with heavier wood.
Conclusion: Choosing the Right Pallet for Your Needs
When pallet weight fluctuates, so do your costs, shipment integrity, and automation success rates. That’s why global manufacturers and logistics providers are moving away from wood—and turning to engineered plastic pallets for their precision, consistency, and lighter, regulation-friendly structures.
At Enlightening Pallet, we don’t just manufacture plastic pallets—we solve weight-related logistics challenges. Whether you need 9 kg export pallets that reduce freight overhead, or 23 kg full-perimeter pallet tailored for ASRS and pooling, we ensure every unit meets your exact pallet weight requirements. No guesswork. No hidden load risks.
We also offer custom weight configurations—from adjusting wall thickness to selective steel reinforcement—designed to fit your automation limits, racking systems, or shipping constraints with precision.
Ready to remove weight-related uncertainty from your supply chain?
✔ Tell us your use case and budget
✔ Get expert advice on structure, load, and max pallet weight
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