Cardboard pallets — also called paper pallets — are shipping pallets manufactured from layers of structural Kraft paper and recycled honeycomb paper core, rather than wood, plastic, or metal. They provide the same load-bearing function as traditional pallets while being up to 80% lighter and 100% recyclable.
Across Europe, more pallets are in circulation than there are people on the continent. The vast majority are wooden. But as supply chains face increasing pressure to reduce weight, cut costs, and meet sustainability targets, cardboard pallets are rapidly moving from niche alternative to mainstream logistics solution.
What Are Cardboard Pallets Made From?
The technical construction of a cardboard pallet typically consists of three components:
- Structural-grade Kraft paper outer — forms the top and bottom decks, providing a water-resistant, load-bearing surface
- Recycled honeycomb paper core — a 10mm cell honeycomb structure sandwiched between the decks, distributing weight evenly and providing compressive strength
- Adhesive bonding — layers are glued rather than nailed, eliminating the risk of protruding fixings that can damage goods or contaminate food-safe consignments
Contrary to common assumption, this construction does not compromise on strength. PALLITE®’s paper-based pallets are engineered to carry comparable payloads to wooden equivalents, without the associated weight penalty.
“We didn’t expect a paper pallet to perform the way it does. The weight saving alone changed the economics of our air freight operation overnight.” — Supply Chain Manager, UK manufacturing business
What Is the Difference Between a Cardboard Pallet and a Wooden Pallet?
The core differences come down to four factors: material composition, weight, regulatory compliance, and end-of-life disposal.
| Factor | Wooden Pallet | Cardboard / Paper Pallet |
|---|---|---|
| Weight | 20–30 kg (typical) | 4–8 kg (up to 80% lighter) |
| Recyclability | Partial (disposal costs apply) | 100% recyclable at kerbside |
| ISPM 15 compliance | Required for export | Exempt — no treatment needed |
| Contamination risk | Splinters, nails, pest harbourage | None — nail-free, splinter-free |
| Air freight saving | Baseline | Up to £60 per pallet |
What Are the Key Advantages of Cardboard Pallets?
1. They Are Fully Recyclable
Paper pallets are manufactured from 100% recyclable materials. Unlike wooden pallets — which incur disposal costs when they reach end of life — cardboard pallets can be broken down and recycled through standard waste streams. For businesses operating within a circular economy framework, this removes a hidden operational cost while directly supporting environmental reporting targets.
2. Significantly Lighter Without Sacrificing Strength
Data suggests that switching from wooden to cardboard pallets can reduce individual pallet weight by as much as 80%. For businesses using air freight, this weight reduction translates directly to cost savings — in some cases up to £60 per pallet per shipment. Over high volumes, this produces a measurable impact on freight spend.
3. Exempt From ISPM 15 Regulations
ISPM 15 is the international phytosanitary standard governing wood packaging used in global trade. It requires wooden pallets to undergo heat treatment or methyl bromide fumigation before crossing international borders — an additional cost and logistical step for exporters. Cardboard and paper-based pallets are entirely exempt from ISPM 15, removing this compliance burden and accelerating customs clearance.
4. Reduced Contamination Risk
Because paper pallets are constructed without nails or staples, they eliminate the risk of metal contamination in transit. They also cannot produce splinters — a particular advantage for food-grade, pharmaceutical, or high-value goods where wooden pallets present a contamination liability.
“The ISPM 15 exemption alone simplified our export documentation considerably. It’s one of those advantages you don’t fully appreciate until you’ve been held up at customs with wooden pallets.” — Logistics Director, UK export business
How Big Are Cardboard Pallets?
Cardboard pallets are available in the same standardised sizes as their wooden equivalents:
- UK / US standard: 120cm × 100cm (48″ × 40″)
- Euro pallet (EUR/EPAL): 120cm × 80cm (48″ × 31″)
Bespoke pallet dimensions are also available for non-standard freight requirements. PALLITE® stocks both UK/US and Euro pallet formats within its range of paper-based pallets, as well as honeycomb shipping crates and layer boards.
What Types of Cardboard Pallet Are Available?
Paper-based pallets are produced in the same structural configurations as traditional pallets:
- Block pallets (four-way entry) — fork access on all four sides, highest manoeuvrability
- Stringer pallets (two-way or four-way entry) — boards connecting top and bottom decks, suited to standard racking
- Double-face pallets — usable either way up, increasing versatility in mixed-load environments
- Solid deck pallets — single continuous top surface, easier to clean, suited to fragile or small-unit consignments
Frequently Asked Questions
Can cardboard pallets hold the same weight as wooden pallets?
Yes. Engineered cardboard pallets using honeycomb paper core construction are capable of carrying comparable loads to standard wooden pallets. Load capacity varies by specification — always confirm with the manufacturer for your specific application.
Are cardboard pallets waterproof?
PALLITE®’s paper pallets use a structural-grade, water-resistant Kraft paper outer. They perform well in typical warehousing and transit conditions but are not designed for prolonged outdoor exposure or immersion. For environments with high moisture risk, speak to the PALLITE® team about appropriate specifications.
Do cardboard pallets need ISPM 15 treatment?
No. Pallets manufactured from paper or cardboard materials are entirely exempt from ISPM 15 phytosanitary regulations, which apply specifically to wood packaging. This makes them the simpler choice for international export.
How much can I save on air freight by switching to cardboard pallets?
Data from PALLITE® customers indicates savings of up to £60 per pallet on air freight routes, attributable to the 80% weight reduction versus wooden pallets. Actual savings will vary depending on freight route, carrier, and shipment volume.
Are cardboard pallets suitable for food and pharmaceutical use?
Yes. The absence of nails, staples, and wood means there is no risk of metal or splinter contamination — making paper pallets a strong candidate for food-grade, pharmaceutical, and cosmetics logistics where hygiene standards are stringent.
Explore PALLITE®’s full range of sustainable paper-based pallets, honeycomb crates, and layer boards at pallitegroup.com/en/pallets/.
