Custom Pallet Sizes Guide 2026
48x48, 42x42, half-pallets, Euro pallets, runner pallets, and custom designs -- specs, pricing, and lead times.
48x48, 42x42, half-pallets, Euro pallets, runner pallets, and custom designs -- specs, pricing, and lead times.
Standard GMA 48x40 pallets serve 80% of the US market. The other 20% -- automotive parts, aerospace components, oversized industrial equipment, specialty chemicals, display-ready retail formats, and pharmaceutical packaging -- requires custom pallet sizes and configurations. Getting the wrong pallet size wrong means load instability, product damage, equipment incompatibility, and retailer chargebacks. This guide covers every common custom pallet size, the industries that need them, how to spec a custom pallet correctly, and lead times and pricing for custom pallet production from Florida Pallet Supply.
Standard GMA 48x40 pallets fail to meet requirements in several scenarios:
| Situation | Problem with 48x40 | Custom Solution |
|---|---|---|
| Oversized product (machinery, HVAC) | Product overhangs excessively on all sides | 60x48, 72x48, or custom large-format pallet |
| Narrow aisle racking (AS/RS) | 48" width may not fit racking entry | 40x32 or custom narrow pallet |
| European container shipments | ISO standard requires 1200x800mm (Euro pallet) | 47.2x31.5 inch Euro pallet |
| Retail floor display (half pallet) | Full pallet too tall for display floor | 48x20 or 40x24 half-pallet |
| Chemical drums (55-gallon) | Drum footprint doesn't match GMA deckboard spacing | 48x48 square pallet for 4-drum configuration |
| Pharmaceutical unit dose trays | Standard pallet overhang creates handling risk | Custom medical-grade pallet with side boards |
| Automotive body panels | Panel width or length exceeds GMA capacity | Custom-length pallet (72x48, 96x48) |
| Carpet rolls | 12-foot carpet rolls require custom runner pallet | Runner pallet: 2 stringers, no deckboards |
| Size (inches) | Common Name | Primary Industries | Notes |
|---|---|---|---|
| 48x40 | GMA Standard | All -- universal | Most available, lowest cost |
| 48x48 | Square / Drum Pallet | Chemical, drum, paint | 4-drum configuration; chemical industry standard |
| 42x42 | Telecom Pallet | Telecom, cable, utility | AT&T, Verizon, and telecom industry standard |
| 40x40 | Dairy / Beverage | Dairy, beverage, CPG | Fits 8-case layer of some beverage formats |
| 48x42 | Grocery / Beverage | Grocery, beer, soda | Common in beverage industry; Anheuser-Busch standard |
| 48x45 | Military / DOD | Defense, government | US military logistics standard pallet |
| 60x40 | Extended GMA | Building materials, HVAC | For products slightly longer than standard 48" loads |
| 60x48 | Industrial Extended | HVAC, machinery, appliances | Common for large appliances and commercial equipment |
| 36x36 | Small Square | Specialty chemical, lab equipment | Quarter pallet equivalent; high-value small loads |
| 48x20 | Half Pallet | Retail display, Costco, Sam's Club | Display-ready; floor merchandising |
| 40x24 | Half Pallet Variant | Retail display, grocery | Alternative half-pallet format |
| 47.2x31.5 (1200x800mm) | Euro Pallet (EUR/EPAL) | European export, pharma | ISO 6780 standard; required for EU market |
| 45.9x45.9 (1165x1165mm) | ISO Pallet | International shipping | ISO 6780 Type 2 -- fits in 20ft ISO containers 2-wide |
| Custom runner pallet | Runner / Carpet Pallet | Carpet, flooring, tube/roll goods | 2-3 stringers only; no top deck; supports rolls |
When requesting a custom pallet quote, provide these specifications:
| Pallet Type | Typical Price Range | Lead Time | Min Order Qty |
|---|---|---|---|
| Standard GMA 48x40 (new) | $18-26 each | Same day - 48hr | 1 |
| 48x48 (new) | $24-34 each | 3-5 business days | 50 |
| 42x42 (new) | $20-28 each | 3-5 business days | 50 |
| Half pallet 48x20 (new) | $14-20 each | 3-7 business days | 50 |
| Euro pallet 47.2x31.5 (new) | $22-32 each | 5-10 business days | 50 |
| 60x48 extended (new) | $32-48 each | 5-10 business days | 25 |
| Runner / carpet pallet (new) | $18-28 each | 5-10 business days | 25 |
| Fully custom (engineered) | $35-100+ each | 7-14 business days | 25-50 |
Custom pallets have longer lead times and minimum order quantities. Plan custom pallet orders 2-3 weeks ahead of need. For one-time projects (trade shows, special shipments), standard size pallets cut to fit are sometimes more cost-effective than full custom production. Florida Pallet Supply can cut standard pallets to custom dimensions for small quantities -- ask about cut-to-size options for orders under 25 pallets.
Yes. Any custom wood pallet can be heat treated to ISPM-15 standards. Heat treatment adds $1-3 per pallet to the cost and requires that the pallet go through our heat treatment chamber after construction. The IPPC mark is stamped on both stringers or blocks after treatment. Certificate of Heat Treatment is available on request for customs documentation. Custom ISPM-15 pallets have a longer lead time than non-treated custom pallets -- factor in an additional 1-3 business days.
Minimum order quantities for custom pallets vary by size complexity. Near-standard sizes (48x48, 42x42, 40x40) typically have a 50-pallet minimum for economical production. Larger or more complex designs (60x48, runner pallets, engineered designs) have minimums of 25-50 pallets. For genuinely unique one-off requirements, Florida Pallet Supply can often accommodate smaller quantities by cutting or modifying standard pallets -- contact us to discuss what's possible for your specific application.
Half-pallets (48x20, 40x24) used for Costco, Sam's Club, Aldi, or Whole Foods floor display are subject to the same Grade A condition requirements as full pallets, with an additional visual standard because the pallet is visible to shoppers. Display half-pallets should be new or near-new Grade A -- no visible staining, clean wood, no odor. Some retailers specify the exact half-pallet dimensions they require -- verify before ordering. Florida Pallet Supply produces display-ready half-pallets to custom specifications.
Yes. Florida Pallet Supply can produce EUR/EPAL-specification pallets (47.24 x 31.50 inches, equivalent to 1200x800mm) on custom order. Euro pallets are most commonly needed for international exports to EU markets, pharmaceutical exports requiring EU GDP pallet compliance, and some pharmaceutical companies with European parent companies who standardize on Euro pallet specifications across all facilities. Euro pallets have a 5-10 business day lead time and 50-pallet minimum. EPAL-stamped pallets (official European Pallet Association certification) are available for shipments requiring EPAL documentation.
Any size, any configuration, ISPM-15 available. 5-10 day lead time FL, GA, NJ, MD, DE.
Florida Pallet Supply delivers new, recycled, and custom pallets across FL, GA, NJ, MD & DE.
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