How to clean and maintain plastic pallets efficiently?

I. The cleaning value of plastic pallets

In the global supply chain, the annual consumption of plastic pallets has exceeded 1 billion. Compared with wooden pallets, their corrosion resistance and easy cleaning properties make them account for up to 68% in industries with high hygiene standards such as food and medicine (according to the Global Logistics Packaging Market Report). But if cleaning management is ignored:

• Food safety risk: The probability of residues breeding pathogens such as Salmonella increases by 300%
• Economic loss: The premature scrapping rate of pallets caused by stain corrosion can reach 25%
• Compliance risks: FDA’s requirement for the number of colonies on the surface of food-grade pallets is ≤100 CFU/cm²

II. Strategic preparation before cleaning

1.  Pallet status diagnosis

• Use an LED flashlight to check cracks (focus on load-bearing bars and support feet)
• Mark stubborn stain areas (yellow labels for oil stains and red labels for mold stains)

2. Tool selection

• Eyewash stations are required in the chemical operation area (within a radius of 15m)
• When using sodium hypochlorite for disinfection, air circulation must be ≥0.3m/s

III. Detailed explanation of the five cleaning technologies

1. Manual cleaning (food grade standard)

• Four-step process: pre-rinsing (40℃ water) → foam covering (neutral detergent) → scrubbing (nylon brush) → terminal disinfection (200ppm chlorine-containing solution)
• Efficiency parameters: 8-10 standard trays (1200×1000mm) can be processed per person per hour

2. Industrial cleaning with the high-pressure water gun

• Pressure gradient control:
  Ordinary dirt: 50-80 Bar
  Solidified grease: 120 Bar + 60℃ hot water
• Water-saving design**: The circulating water system can reduce water consumption by 90%

3. Ultrasonic precision cleaning (medical grade)

• Parameter setting:
  Frequency: 40kHz (removal of particles)
  Temperature: 50℃ (activation of detergent)
  Time: 8-12 minutes/batch
• Verification standard: ATP bioluminescence detection value <50 RLU

4. Golden ratio of chemical disinfection

5. Automated cleaning line design

• Module configuration: pre-wash → main wash (spray pressure 0.3MPa) → rinse → hot air drying (70℃)
• Capacity benchmark: Chain conveyor system can reach 800 pallets/hour

IV. Industry customized solutions

1. Food processing industry

• Critical control points:
  Weekly microbial testing (E. coli must not be detected)
  Establish a cleaning record traceability system (retained for ≥2 years)

2. Pharmaceutical industry

• GMP compliance points:
• Use WFI (water for injection) for terminal rinse
• Cleaning validation must include API residue detection

3. Chemical logistics

• Material compatibility testing:
  HDPE pallets must be resistant to chemicals with pH 2- 12
  Impact strength retention rate after cleaning ≥95%

V. Full life cycle management strategy

1. Digital monitoring

• Implant an RFID chip to record the number of cleaning times (recommended ≤200 times/pallet)
• Use stress sensors to monitor structural deformation (threshold set to 85% of initial load)

2. Green maintenance technology

• Microbial cleaners (including Bacillus) decompose organic stains
• UV aging repair coating (spraying once a year extends the service life by 3 years)

3. Scrap judgment criteria

• Crack length > 50mm or depth > 2mm
• Flatness deviation > 10mm/m

VI. Benefit analysis
The implementation of scientific cleaning solutions can achieve:

• Reduced sanitation costs: 45% reduction in cross-contamination accidents
• Improved economic benefits: Extended service life of pallets from 5 years to 12 years
• Environmental value creation: 380 tons of water saved per thousand pallets per year

By establishing a closed-loop management system of cleaning-testing-maintenance, enterprises can not only meet the requirements of ISO 22000, GDP and other regulations, but also shape sustainable supply chain competitiveness.