Replacing a wooden pallet with a plastic one is a common practice in warehouses and manufacturing facilities. Plastic pallets are more hygienic, more durable, and mandatory in certain sectors, such as the food industry or the pharmaceutical sector. The challenge is that the load is already on the wooden pallet and must be transferred safely without damage or risk. With the right preparation and the right equipment, this pallet swap goes smoothly and safely.
This guide walks you through the process of replacing a wooden pallet with a plastic pallet step by step, from preparation to the final inspection. The most efficient method involves using a pallet inverter, also known as a pallet turner or pallet-turning machine.
What You Need for the Pallet Change
Make sure you have everything you need on hand before you begin. Proper preparation prevents interruptions during the pallet change and reduces the risk of errors or accidents.
- A pallet inverter (pallet-turning machine) that is suitable for the weight and dimensions of your load
- A plastic pallet of the correct size, typically 800×1200 mm or 1000×1200 mm
- The wooden pallet with the cargo to be replaced
- A pallet jack or forklift to move the pallet
- If necessary, use plastic wrap or strapping to stabilize the load after the transfer
- Personal protective equipment: safety shoes and, if necessary, gloves
Also check whether the load is stable enough to be tilted. Loose or fragile items require additional securing before you perform the pallet change. If the goods are not stabilized, first make sure to wrap them securely with plastic film or strapping.
Get the wooden pallet ready for the switch
Before changing the pallet, it is important to ensure that the wooden pallet is positioned correctly and that the load is securely fastened. Do not skip this step: an unstable load could shift or fall during the tilting process.
- Check the condition of the wooden pallet. Are there any broken boards or protruding nails? If so, take the pallet out of service and replace it with an intact one.
- Check to make sure the load is evenly distributed on the pallet. A pallet loaded unevenly can cause problems during the swap.
- Secure the load with plastic wrap or straps as needed so that the products cannot shift while the vehicle is tilted.
- Drive the pallet truck or forklift under the wooden pallet and move it to the feed side of the pallet inverter.
After this step, the loaded wooden pallet is ready to be fed into the pallet inverter. The load is stable, and the pallet is undamaged. You can now proceed with the actual pallet change.
Perform the pallet change using a pallet inverter
The pallet inverter is the key tool for changing pallets. The machine tilts the entire load, including the pallet, 180 degrees so that the wooden pallet ends up on top and can be easily removed. The plastic pallet is then placed underneath, and the load is rotated back into position.
- Drive the loaded wooden pallet into the pallet inverter. Make sure the pallet is properly centered in the machine.
- Close the clamps or pressure plates on the pallet inverter so that the load is held securely in place during tilting.
- Activate the tilt function. The machine rotates the load 180 degrees, so that the wooden pallet is now on top.
- Remove the wooden pallet from the top. This can be done manually or with a forklift, depending on the machine's configuration.
- Place the plastic pallet on the exposed top surface of the load. Make sure it is centered properly.
- Rotate the pallet inverter back to its starting position. The load is now on the plastic pallet.
- Open the clamps and drive the pallet with the plastic sub-pallet out of the machine.
After tilting, the load is on the new plastic pallet. Visually check to make sure the load is still properly centered and that nothing has shifted during the tilting process. If everything is in order, the pallet change is technically complete.
Check the load after the changeover
A thorough final inspection is essential after every pallet change. Even when the process is carried out correctly, products may shift slightly or the wrap may come loose. Always take a moment to do this.
- Visually inspect the shipment from all sides. Have any items shifted, fallen, or been damaged?
- Check the plastic wrap or strapping. If it has come loose or is damaged, replace it with new plastic wrap or strapping.
- Check the plastic pallet yourself. Is the load distributed evenly, and is the pallet undamaged?
- Weigh the pallet again if necessary, for example, if the load has been sorted or redistributed.
Only once all the requirements have been met will the wooden pallet be replaced with a plastic pallet and be ready for further processing, storage, or transport. Store the wooden pallet in the designated location or dispose of it if it is damaged.
Common Problems When Changing Pallets
Even with the right machine and proper preparation, problems can arise during pallet changes. Below are the most common issues and how to resolve them.
The load shifts during tipping
This occurs when the load is not secured properly or when the clamping force of the pallet inverter is not set correctly. Always check the stretch wrap before tilting and adjust the clamping force according to the weight and fragility of the products. Extra caution is required when handling fragile goods such as glass or electronics.
The wooden pallet is difficult to remove
Sometimes the boards of a wooden pallet are jammed or slightly warped. Never use excessive force to pull the pallet free. Check to make sure the machine is fully tilted and that no products are blocking the pallet. If this happens repeatedly, the cause may also be an incorrect pallet size.
The plastic pallet doesn't fit properly
Always check in advance to make sure the dimensions of the plastic pallet match those of the load and the pallet inverter. Preferably use standardized pallet sizes that are compatible with the machines and racking in your warehouse. You can find more information about proper applications on the pallet handling page.
The machine displays an error message or stops
In the event of technical malfunctions, always consult the pallet inverter manual. Turn off the machine and check for any obstructions or to see if a safety switch has been activated. Never disable the safety features on your own. If in doubt, contact the service department.
How Logitrans Handling Helps with Pallet Changes
Replacing a wooden pallet with a plastic one correctly and safely requires the right machine, the right settings, and knowledge of the process. We offer a full range of solutions tailored to your specific situation.
- Customized advice: Our specialists analyze your workstation and recommend the most suitable pallet inverter, taking into account the weight, dimensions, and type of load.
- Extensive product range: From compact pallet inverters for light loads to heavy-duty industrial models for demanding environments, our product lineup covers every application.
- Free Workstation Analysis: We'll come to your location to assess your situation and propose a concrete solution, with no obligation.
- Demo in Drongen: You can test our machines in our demo area using your own materials, so you can be sure you’re making the right choice.
- Maintenance Contracts: We ensure that your machines remain in top condition through our service department, so that safety and productivity are guaranteed.
Would you like to know which solution best suits your pallet-changing process? Contact us, and our specialists will be happy to assist you.
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