When it comes to choosing the right pallets for brick, block, and paver manufacturing, the decision can significantly impact your production efficiency, costs, and long-term profitability. In this comprehensive comparison, we’ll analyze three popular options: PAC Pallets, Low Cost Recycled Plastic Pallets, and Composite Wooden Pallets.
Here’s a side-by-side breakdown of how they compare — and why PAC® Pallets offer better long-term value.
1. Low Cost Recycled Plastic Pallets: Low Price, Lower Performance
At first glance, Low Cost Recycled Plastic Pallets seem budget-friendly. They are typically priced at ₹50–70 per square foot, making them attractive for short-term use.
But here’s the trade-off:
- Made from low-grade, post-consumer plastic, which has poor structural strength.
- Average service life is just 2–3 years before cracking, warping, or losing load capacity.
- Vulnerable to UV degradation, chemical damage, and deformation under heavy loads.
- Non-uniform quality due to inconsistent recycled feedstock.
- Limited recyclability after use — often ending up in landfills.
Impact on Brick manufacturing
In brick manufacturing, every rejected batch eats into profit. Low-cost recycled pallets often bend or crack under the weight of fresh fly ash bricks, leading to uneven curing, chipping, and breakage. The result? High rejection rates, wasted labour, and lost production hours. What looked “budget-friendly” at purchase ends up draining margins.
2. Composite Wooden Pallets: Strong Claims, Weak Reality
Composite wooden pallets often market themselves as a stronger alternative, sometimes with metal reinforcement grids inside and a surface coating for a polished finish. Typical cost: ₹120 per piece.
Key issues:
- The internal metal mesh offers no load-bearing improvement — more cosmetic than functional.
- Surface coating wears off in 2–3 years, leaving the pallet exposed to moisture and pest damage.
- Recoating or refurbishing costs are high, making maintenance expensive.
- Still vulnerable to termites, swelling, and warping in humid or wet environments.
- Not fully recyclable — wood composites with metal and adhesives are difficult to process at end-of-life.
Impact on Brick manufacturing
These pallets may arrive with a smooth, professional finish — but the reality sets in quickly. Being plywood-based, they absorb water moisture and weather exposure. The coating wears off, and pallets start warping or breaking, making them unsafe for labourers to handle. Inconsistent support directly impacts brick quality, leading to deformation and shorter shelf life in storage or transit.
3. PAC® Pallets: Long-Life, High-Performance, and Sustainable
Rajratan’s PAC® (Plastic-Aluminium Composite) Pallets are designed for heavy-duty industrial use, these pallets are individually designed and molded according to customer requirements and machine specifications.
Key specifications:
- Price: ₹120/ sq ft.
- Composition: Industrial-grade plastics (PP, LDPE & HDPE), Aluminium Oxide, Fibres, and XLP metals — moulded individually for precision.
- Service life: Up to 10 years (depending on usage).
- Properties:
- Waterproof, UV resistant, termite-proof, and acid-resistant
- Strong and durable — does not crack, deform, or degrade
- Easy to clean and hygienic for food and pharma industries
- Fully recyclable at end-of-life
- Additional value: 40% buyback guarantee, custom sizes available.
Impact on Brick manufacturing
Built for industrial toughness, PAC® Pallets are engineered to handle the heavy load of green bricks without bending or absorbing moisture. Their waterproof, warp-proof, and dimensionally stable design ensures uniform curing, reduced breakage, and lower rejection rates .
For safety, every PAC® Pallet is precision-cut with 45° angled corners, eliminating sharp edges that can injure labourers during handling. Over time, PAC® Pallets cut operational losses and maintain consistent brick quality — delivering reliability the industry can count on.
Side-by-Side Comparison
Feature | Low-Cost Recycled Plastic Pallet | Composite Wooden Pallet | PAC® Pallet |
Price | ₹50–70 / sq.ft | ₹120 / piece | ₹120 / sq.ft |
Material | Low-grade recycled plastic | Plywood core + coating + metal mesh | Industrial-grade plastic + aluminium oxide + fibres + XLP metals |
Service Life | 2–3 years | 2–3 years (before recoating) | Up to 10 years |
Load Resistance | Low — bends or cracks under fresh brick weight, causing high rejection rates | Moderate initially — drops sharply once coating wears, leading to warped pallets and damaged bricks | High and consistent throughout lifespan |
Maintenance | Frequent replacement | Costly recoating and repairs | Minimal |
Hygiene | Poor — prone to surface contamination | Poor after coating wears | Excellent — non-porous and easy to clean |
Recyclability | Limited | Very low | 100% recyclable |
Weather & Water Resistance | Poor — degrades quickly in sun/rain | Moderate — coating slows but does not prevent water damage | Excellent — unaffected by moisture and weather |
Labour Safety | No design safety features; sharp edges | Edges chip and splinter after wear | 45° angled corners prevent injury during handling |
The Long-Term Value Argument
While PAC® Pallets cost more upfront than cheap alternatives, the extended service life, lower maintenance, and buyback option make them more cost-effective over a 10-year period.
For example:
- Replacing Low Cost Recycled Plastic Pallets every 3 years over 10 years = 3 full purchases + disposal costs.
- Replacing composite wooden pallets every 3 years (with recoating) costs even more in refurbishing.
- PAC® Pallets = one purchase, with high resale value at end-of-life.
Conclusion: Invest in Performance, Not Just Price
In fly ash brick, concrete block, and paver production, pallets are not just platforms — they are critical tooling. The wrong pallet can slow production, damage products, and add costly downtime. The choice is clear:
- Low Cost Recycled Plastic Pallets fail too soon.
- Composite wooden pallets cost more to maintain than they’re worth.
- PAC® Pallets deliver strength, hygiene, and sustainability for the long run.
For more information about PAC® Pallets and custom solutions, contact Rajratan Industries Private Limited – India’s largest manufacturer of composite pallets for brick, block & pavers.
Know more about PAC® Pallet – Rajratan PAC® Pallet
- Phone: 0731 4045302
- Mobile: +91 96857 27927
- Email: info@rajratan.in