The brick and paver block manufacturing industry in India is tough. It is a sector where margins are tight, and the machinery takes a beating every single day. For years, manufacturers have struggled with one specific component that seems small but causes the biggest headaches: the pallet.
If you run a brick plant, you know the pain. Wooden pallets rot and absorb water. Plywood swells up and de-laminates. Steel plates are heavy, rust easily, and can get bent out of shape, ruining the finish of your bricks. This is where the industry is seeing a massive shift. The solution isn’t wood or pure metal anymore; it is the PAC® Pallet.
Manufactured by Rajratan Industries, PAC® (Plastic Aluminum Composite) Pallets are quickly becoming the standard for factories that want to stop replacing their boards every six months.
What Actually is a PAC Pallet?
The term “PAC” stands for Plastic Aluminum Composite. Unlike standard PVC boards that can crack under pressure, a PAC® Pallet is an engineered product designed specifically for the heavy vibrations and pressure of brick-making machines.
According to the manufacturing specs, these pallets are not just a single slab of plastic. They are a composite board made from a very specific mix:
- Industrial Grade Plastics: A blend of PP, LDPE, and HDPE (High-Density Polyethylene).
- Aluminium Oxide: This adds significant rigidity.
- Fibres: For internal bonding strength.
- XLP Metals: To handle the load.
This unique mixture means the board is made from industrial plastics but reinforced to behave like a much stronger material. Each pallet is moulded separately, which ensures that every single board that comes out of the factory has the exact same thickness and density.
The Core Problem: Water and Weight
In paver manufacturing, water is everywhere. You need it for the mix, and you need it for curing. Traditional plywood pallets are a nightmare in this environment. They soak up moisture, they get heavy, and eventually, they rot.
The biggest advantage of shifting to PAC® Pallets is that they are completely waterproof. They do not absorb a single drop of water. This has two massive benefits for a factory owner:
- Consistent Curing: Since the pallet doesn’t suck moisture out of the wet brick, your bricks cure evenly.
- Cleanliness: They are easy to clean and do not grow fungus or moss like wet wood does.
Additionally, they are UV resistant. Many yards store their pallets out in the open sun. Regular plastic gets brittle and cracks after a summer in the Indian heat. PAC® pallets are chemically stabilized to handle UV exposure without degrading, cracking, or deforming.
Choosing the Right Board: It’s Not “One Size Fits All”
One of the most interesting details from Rajratan Industries is that they don’t just sell one “PAC® Pallet.” They have engineered three different types of boards to fit specific machines. This is important because a manual vibrating table puts very different stress on a board compared to a high-pressure hydro machine.
Here is the breakdown of the three variants available:
1. Fibre Reinforced Board
This is the entry-level workhorse, perfect for lighter applications.
- Composition: It is Mix Plastic, Aluminum Oxide, and Cotton Fibre .
- Best For: Top Press Hydro Machines and Vibrating Table Systems.
- Lifespan: You can expect a service life of 3 to 4 years.
- Thickness Options: 12mm, 18mm, and 21mm.
If you are making Fly Ash Bricks or Reflective Pavers, this board offers great value.
2. Metal Reinforced Board
This is for the heavy-duty user who needs more stiffness.
- Composition: The plastic drops to , Aluminum Oxide goes up to , and they introduce XLP Metals .
- Best For: Imported Vibro Machines and Hydro Vibro Machines.
- Lifespan: The service life jumps to 5 to 6 years.
- Thickness Options: 18mm, 21mm, and 25mm.
This is the recommended choice if you are producing heavy pavers or hollow blocks.
3. Steel Reinforced Board
This is the strongest pallet in their lineup, designed for maximum load-bearing capacity.
- Composition: It shares the base mix of the Metal Reinforced board Plastic, Aluminium Oxide, XLP Metals) but adds a Steel Tube Frame inside the board with a 2.5 to 3mm wall thickness .
- Best For: Multi-Product Vibro Machines.
- Lifespan: These are built to last 7 to 10 years.
- Thickness Options: 25mm and 30mm.
This is the ultimate solution for factories making solid blocks, large hollow blocks, and other cement-based products where the weight would snap a lesser board.
The Economics: Buyback and Longevity
Let’s talk about money. Investing in quality pallets is a significant capital expenditure for a factory. However, the math with PAC pallets works out in favour of the manufacturer in the long run.
First, look at the service life. A standard wooden pallet might last a year if you are lucky. PAC® pallets are rated for a service life of up to 10 years depending on the usage and model. Even the basic Fibre Reinforced board gives you 3-4 years of service.
But the real financial safety net is the Buyback Replacement policy. Rajratan Industries offers a 40% buyback value. This means that when your pallets eventually wear out after years of service, they aren’t just trash. You can return them to the manufacturer and get 40% value back towards your new stock.
Technical Superiority in Design
It isn’t just about the material; it is also about how the pallet interacts with your machine.
If you look closely at the design features, Rajratan has included Corner Fillets for evenly thick edges. This might seem like a minor detail, but in a high-speed production line, sharp corners are the first thing to chip and break. A filleted (rounded/reinforced) edge ensures smooth handling and significantly reduces wear and tear during the stacking and feeding process.
Furthermore, these pallets are additionally sanded. A sanded surface provides the right amount of friction—holding the wet mix in place during vibration so it doesn’t slide off, but still releasing the cured brick cleanly when it’s time to de-mould.
The pallets are designed to be Strong & Durable , and because they are moulded individually, they offer better weight-holding capacity compared to sheets that are just cut from a larger block.
A Proven Track Record
When trying a new technology, trust is usually the biggest barrier. PAC Pallets aren’t a new experiment. Rajratan Industries has 25+ years of experience in this field. They are currently India’s largest manufacturer of composite pallets for brick, block, and pavers.
Their scale of operation is massive:
- Supplied: Over 50 Lakh+ pallets.
- Customers: More than 4,000 satisfied customers.
- Reach: A network covering 200+ cities across 24 States and 6 Union Territories .
They supply to major machinery brands and clients like Apollo, Neptune, Hi-Tech, Q Green, and Revomac, which proves that the leading machine manufacturers trust these pallets to run on their equipment.
Conclusion: Is It Time to Switch?
For a brick manufacturer, the pallet is the foundation of production. If your pallet is weak, your brick is weak. If your pallet is warped, your brick is crooked.
The shift toward PAC Pallets represents a move toward modernization in the Indian construction industry. By moving away from wood and steel to Plastic Aluminum Composite, manufacturers are getting a product that is waterproof, durable, and economically smart thanks to the buyback policy.
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