Production Process for Spill-Containment Pallets

Plastic pallets can be molded using the following four methods:
First: Injection Molding.
Plastic pallets produced using this method are flat, smooth, crisp, and dense, offering greater design freedom. They are categorized into double-sided, monolithic plastic pallets and double-sided, assembled plastic pallets.
Double-sided, monolithic pallets generally weigh over 15 kg per piece and have complex shapes, requiring injection molding machines with a clamping force of over 2,500 tons. This type of pallet, while complex in shape, requires significant investment and relatively high costs. However, due to the reduced number of production steps, it offers relatively high production efficiency and superior product quality. This method is not widely used by general plastics processing plants.
Double-sided, assembled pallets are constructed by dividing a monolithic pallet into two separate pieces, which are injection molded separately and then assembled. Although this product requires two molds, the mold structure is significantly simplified, making the total mold investment less expensive than monolithic pallets. Furthermore, the clamping force requirement is lower, requiring a clamping force of 1,500 tons or more, making it readily available to general plastics processing plants. This production method is likely to become the mainstream in plastic pallet production. Second Method: Extrusion-Blow Molding.
Extrusion-blow molding of plastic pallets is similar to conventional blow molding methods for hollow products. However, due to the larger size and double-sided design of the product, a larger extruder, clamping machine, and molds are required. Domestic blow molding machine manufacturers have developed ultra-large blow molding machines specifically designed for high-speed production of high-strength blow-molded pallets. These machines, made from high-strength HMWHDPE plastic, offer rapid molding speeds, high product quality, high strength, high rigidity, and a very long service life. Blow-molded pallets typically have a service life of 5-10 years and can operate stably in environments ranging from -40°C to 40°C. They can withstand dynamic loads exceeding 3 tons and exhibit high bending strength. They are the preferred choice for applications requiring a long life and high-intensity use. While their price is higher than other plastic pallets, their exceptionally long service life offers the best value for money. With the significant price reduction of molding equipment, this method offers significant advantages in conserving limited petroleum resources and reducing logistics costs.
Third Method: Vacuum Forming. Plastic pallets produced using the vacuum forming method come in both single-sided and double-sided types. Single-sided pallets are primarily used for packaging and transporting small motors (such as vacuum cleaner motors and power tool motors) and cable trays. They have seen rapid growth and are primarily specialized. Double-sided pallets are assembled and come in two forms: the upper half is an extruded plastic sheet of fixed length and width, and the lower half is a large vacuum forming product; or both the upper and lower halves are large vacuum forming products. This method requires large vacuum forming equipment, which is relatively inexpensive, as are mold costs. However, the product wall thickness is uneven.

The fourth method is extrusion forming. Plastic pallets produced using this method are assembled. Using an extruder and die, the upper and lower panels are extruded separately, along with the I-shaped connecting plate with double wings for support. These are then assembled. The emergence of wood-plastic composite materials has driven the development of extrusion-molded plastic pallets. Made primarily from natural plant fibers (including wood flour, nutshells, straw powder, and rice chaff) and waste plastic, this pallet retains the feel of wood while also being water-resistant and pest-resistant. It can also be planed, sawed, and nailed. Of the four molding methods, this one requires minimal investment in equipment and molds, resulting in the lowest cost and the best price-performance ratio. Production of this product is already underway in Beijing and Guangdong.