ZHONGYUE MOULD manufactures Plastic Heavy Duty Pallet Mould for rackable, stackable, reusable, and high-load plastic pallet designs. The moulds are used for logistics, warehousing, industrial handling, export shipping, and other applications where the pallet requires a reinforced structure and stable dimensions.
The mould design is developed from the pallet size, deck structure, rib layout, load requirement, plastic material, production quantity, and injection machine conditions. PP and HDPE are commonly used, while recycled plastic can also be considered according to the pallet design and production requirements.
| Pallet Size |
400 × 300 mm 600 × 400 mm 800 × 600 mm 1200 × 800 mm 1200 × 1000 mm 1200 × 1200 mm Up to 1500 × 1500 mm |
| Pallet Material | HDPE, PP, recycled plastic |
| Pallet Types | Nestable pallet, stackable pallet, hygienic pallet, export pallet, single-face pallet, double-face pallet, rackable pallet |
| Load Capacity |
Light duty: up to 500 kg Medium duty: 500–1000 kg Heavy duty: over 1000 kg, up to 2500 kg for special applications |
| Mould Name | Plastic Heavy Duty Pallet Mould |
| Mould Steel | P20, 2738, 718H, NAK80, 2316, S136, H13 and other grades according to requirements |
| Mould Base | Self-made, LKM, DME, ASSAB |
| Cavity | Single cavity or multi-cavity |
| Runner System | Cold runner and hot runner |
| Hot Runner Brands | MASTER, Husky, YUDO and other brands according to requirements |
| Design Software | UG, AutoCAD and related mould design software |
| Mould Life | 50–100 million shots / 5–6 years, and up to 10 years with proper maintenance |
| Typical T1 Lead Time | Approximately 45–60 days |
| Plastic Materials | PP, ABS |
| Gate Types | Pinpoint gate, edge gate, sub gate, film gate, valve gate, open gate and others |
| Mould Surface Treatment | EDM, texture, high-gloss polishing |
| Quality System | ISO 9001 |
| HS Code | 8480719090 |
| Origin | Huangyan, Zhejiang, China |
| Packaging | Wooden case |
Heavy duty plastic pallets are available in different structures depending on the required load, storage method, handling equipment, and application. The deck, ribs, runners, support blocks, and fork-entry areas all affect the mould design.
| Pallet Type | Structural Features | Typical Applications |
| Rackable Pallet | Reinforced deck and support areas for use with warehouse racking systems | Warehousing, distribution centers, industrial storage |
| Heavy Duty Single-face Pallet | Single deck with reinforced ribs, runners, and load-bearing sections | Industrial handling, material transport, repeated use |
| Heavy Duty Double-face Pallet | Two-sided deck structure with reinforced internal support sections | Heavy-load handling, reusable logistics, industrial applications |
| Nestable Pallet | Tapered support legs allow empty pallets to be nested together | Export shipping, transport, storage, return logistics |
The mould is developed around the actual pallet geometry. Deck thickness, rib distribution, support positions, fork openings, draft angles, and other functional areas are reviewed before the mould structure is finalized.
Heavy duty pallets usually have a large deck area combined with ribs, support blocks, and thicker structural sections. The gate and runner layout needs to provide suitable filling conditions across these areas.
Hot runner or cold runner systems can be selected according to the pallet geometry, material, injection conditions, and production requirements. For larger or more complex designs, Moldflow or other CAE analysis can be used to review filling behavior, weld-line positions, and pressure distribution before machining.
The cooling system has an important effect on cycle consistency and pallet dimensions. Thick ribs and support blocks can cool differently from the main deck, which may lead to uneven shrinkage if the cooling arrangement is not properly considered.
Cooling channels are arranged according to the core and cavity structure. Separate circuits can be used for different mould areas when independent temperature control is required. Copper-alloy inserts can also be considered for sections where heat removal is more difficult.
A large pallet part requires sufficient ejection force distributed across suitable areas. Ejector pins, ejector blocks, stripper components, or combined systems can be used according to the pallet structure.
The ejection points are positioned around reinforced sections where possible. The system is designed together with the draft angles, cooling circuits, mould opening direction, and other moving components to support stable demoulding.
Some heavy duty pallet designs include side openings, undercuts, or special fork-entry structures that cannot be formed directly by the main core and cavity. Slides, lifters, side cores, or replaceable inserts can be used where required.
The movement and clearance of these components are checked during mould design, with attention to guidance, wear, maintenance, and access for future replacement.
Mould steel is selected according to mould size, production volume, plastic material, surface requirements, and expected service conditions. P20, 2738, 718H, H13, S136, and other grades can be considered for different mould applications.
| Mould Steel | Typical Hardness | Typical Use |
| P20 | HRC 28–33 | Standard production applications |
| 718H | HRC 33–36 | Higher production volumes and general wear resistance |
| H13 | HRC 43+ | Applications requiring higher wear and heat resistance |
| 2344 | HRC 48+ | High-wear mould applications |
| S136 | HRC 48–52 | Applications requiring corrosion resistance and suitable surface quality |
The final steel grade is confirmed according to the mould structure, production conditions, and required service life.
The mould manufacturing process starts with the pallet drawing, 3D model, physical sample, or technical specification. The available product information is reviewed before the mould structure and machining plan are confirmed.
The engineering review covers pallet dimensions, wall thickness, ribs, support areas, draft angles, fork openings, parting lines, gate positions, cooling circuits, and ejection requirements.
For large or complex pallet designs, filling and cooling analysis can be carried out before machining. The results can be used to review potential filling imbalance, weld lines, air traps, pressure differences, and cooling variations.
Core, cavity, inserts, slides, and other mould components are machined according to the approved drawings and 3D data. CNC machining, EDM, wire cutting, drilling, grinding, and other processes are selected according to the component structure.
After machining, the mould components are assembled and checked. Cooling circuits, runner components, guide systems, side actions, and ejection components are inspected before the mould trial.
The first mould trial is used to check mould operation and the initial pallet samples. Filling, dimensions, demoulding, ejection, appearance, and other agreed inspection items are reviewed before any required adjustments are made.
Heavy duty plastic pallets are used for material handling, storage, and transport where the pallet is exposed to repeated use or higher load requirements. Typical applications include:
The pallet structure and material are selected according to the load requirement, handling equipment, storage method, and working environment.
Mould inspection is carried out during machining, assembly, and trial production. Depending on the project requirements, inspection may include steel documentation, component dimensions, mould assembly, cooling circuits, mould opening and closing, ejection movement, and trial samples.
Dimensional reports, steel certificates, and trial information can be provided for custom pallet mould projects according to the agreed inspection requirements.
ZHONGYUE MOULD develops custom moulds from pallet drawings, 3D models, physical samples, or technical specifications. The engineering review considers the pallet size, deck structure, load requirement, plastic material, production volume, injection machine, and required mould life.
For a new pallet design, the mould can be developed from the available product drawings and specifications. For an existing pallet, a physical sample or existing mould information can be used as a reference.
The final mould specification may include the steel grade, mould base, cavity structure, runner system, gate arrangement, cooling system, ejection system, side actions, and T1 schedule.
The following information can be provided when requesting a quotation for a heavy duty pallet mould:
If a complete drawing is not available, an existing pallet sample, product dimensions, or basic technical information can be used for an initial engineering review.
ZHONGYUE MOULD is a plastic injection mould manufacturer based in Huangyan, Taizhou, Zhejiang, China. The company develops and manufactures injection moulds for automotive, household, home appliance, logistics, and other plastic products.
For large-format mould projects, the production process includes product and mould design, steel selection, CNC and EDM machining, mould assembly, trial moulding, inspection, and technical support.
A heavy duty pallet mould is an injection mould used to produce plastic pallets with reinforced decks, ribs, runners, support blocks, or other structural features for higher-load and repeated-use applications.
HDPE and PP are commonly used for plastic pallets. Recycled plastic can also be considered when the material properties are suitable for the pallet design and production process.
Yes. Rackable pallet moulds can be developed according to the required deck structure, support areas, ribs, dimensions, and storage conditions.
P20, 2738, 718H, H13, S136, 2344, and other suitable mould steels can be selected according to mould size, production volume, material, surface requirements, and expected service life.
The typical T1 lead time is approximately 45–60 days. The actual schedule depends on mould size, pallet structure, steel, runner system, cooling arrangement, side actions, and other project conditions.
A pallet drawing, 3D model, physical sample, dimensions, plastic material, load requirements, production quantity, required mould life, and injection machine information can be used for project evaluation.
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No.38, Kaituo Road Xinqian Street, Huangyan Taizhou City, Zhejiang Province, China
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