Bulk plastic pallets, sized by the trailer
Bulk, in trailers
- Unit
- The 53 ft trailer
- Example, 48 x 40 nestable
- 1,260 per trailer (Rehrig standard-duty)
- Example, rackable
- 540 per trailer (Rehrig)
- Dealer figure
- 30 stacks, turned pattern, dry van
- Stated here
- No price, minimum or lead time
Bulk plastic pallets are bought by the trailer, not by the piece. One dealer puts 30 stacks of 48 x 40 pallets on a 53 ft dry van in a turned pattern, so the order that matters is the trailer count, and the pallets per stack come from the model.
Use the planner to compare published examples, then send the ship-to ZIP, the footprint and the number of trailers. We write the load and say whether it is a one-time order or a standing supply.
Why trailer counts differ so much
Compare two 48 x 40 models from the same maker: the standard-duty nestable is 26.5 lb and ships 1,260 to a trailer; the rackable is 44.2 lb and ships 540. The nestable lists a 2.50 in nest increment, so each extra pallet in a stack adds only that much height. The rackable lists no nest increment, and it is the heavier pallet.
| Model class | Published example | Why the count moves |
|---|---|---|
| Lightweight nestable | 2,340 per truckload (Premier Pallet EXP 100, 78 per stack) | Short nest increment and a light build |
| Nestable, stackable, rackable | 1,800 per truck (Nelson, about 60 per stack) | Nests, yet also racks |
| Standard-duty nestable | 1,260 per trailer (Rehrig) | Deep nest, no rack rating |
| Heavy-duty nestable | 1,200 per trailer (Rehrig) | 2.55 in nest increment |
| Rackable | 540 per trailer (Rehrig) | Heavier build; no nest increment listed |
What we ask for to size a bulk load
Nelson Company's request form asks how many pallets are needed in bands of under 100, 100 to 500, 500 to 1,000 and 1,000 or more, and whether the need is one-time or recurring. We ask the same two things in the same spirit, and then go further because a trailer is the unit that matters:
- The ship-to ZIP, so we plan the lane.
- The footprint, from the sizes hub.
- The number of trailers, or the pallet count and we convert.
- The use, so the resin and papers fit.
- One-time or recurring.
One-time load or standing supply
A one-time order is a single trailer, written and shipped. A standing supply is a rule: the same model, the same ratings and the same resin on every load. Pallets that go out and come back in a closed loop need exactly that. Tell us which in the form. A standing account is written once and every later order refers to it.
We do not state a minimum quantity. No offer sheet exists, so any number here would be invented.
From a published count to an order
| Model (empty, nested) | Per trailer | 5 trailers | 10 trailers | 20 trailers |
|---|---|---|---|---|
| Rehrig standard-duty nestable | 1,260 | 6,300 | 12,600 | 25,200 |
| Rehrig heavy-duty nestable | 1,200 | 6,000 | 12,000 | 24,000 |
| PHS EXP 116 | 1,260 | 6,300 | 12,600 | 25,200 |
| Nelson nestable, stackable, rackable | 1,800 | 9,000 | 18,000 | 36,000 |
| Rehrig rackable | 540 | 2,700 | 5,400 | 10,800 |
| PHS EXP 100 lightweight | 2,340 | 11,700 | 23,400 | 46,800 |
The columns are multiplication of the published per-trailer count, nothing more. A real order is limited by the delivery point, the trailer used and the maker's stock, so the quote states a count for the model and the number of trailers that fits the load.
Planning a bulk order
A bulk order is planned backwards from the trailer. Fix the footprint, find the count per trailer, then multiply by the number of trailers and the number of ship-to docks. Ask whether the lot can be split across several delivery months, since a standing supply is easier to schedule than a single large drop.
From request to trailer
- Send the ship-to. A delivery ZIP, a footprint and a quantity, in pallets or in trailers. If you do not know a rating, describe the load.
- We match a model. We pick a maker and model whose published static, dynamic and racking load fit the load, and say so when only one maker fits.
- You get a count. The quote carries the maker's own per-trailer figure where one is published, and says plainly where none is.
- Papers and delivery. For food or pharma we attach the resin and colourant documents. A standing supply repeats the same line on every order.
What a complete request carries
- The footprint, in inches or millimetres, and whether it is fixed by a rack bay or a container.
- How many pallets, or how many 53 ft trailers.
- The ratings the load needs: static for the stack, dynamic for the move, racking only if the pallet sits on beams.
- Food, pharma, chemical, automotive, warehouse or export use, which sets the papers.
- One load now, or a standing supply with the same line on every order.
- Where it goes and when, and anything marked on the pallet: colour, logo, RFID tag.
Terms on this page
- Nestable
- Empty pallets stack inside one another, cutting empty storage space by up to 75 percent.
- Nest increment
- How much height each extra nested pallet adds to a stack.
- Closed loop
- Pallets that travel between known sites and come back, so they are never lost to a downstream user.
- PP
- Polypropylene. More rigid than HDPE and better with heat and harsh chemicals; used where rack stiffness matters.
- Stackable
- Loaded pallets can sit on top of each other, up to the static rating.
- Rackable
- Rated to sit on rack beams, with a stated racking load.
- Dynamic load
- Weight a pallet carries while moving on a forklift, pallet jack or conveyor.
- Racking load
- Weight a pallet carries bridging an open span in unsupported racking. Often the lowest rating.
- HDPE
- High-density polyethylene, resin code 2. The most common resin in plastic pallets; tough and moisture resistant.
- 4-way entry
- Forks or a jack can enter from all four sides.
Questions at the dock
Where can I buy plastic pallets in bulk?
From a supplier that orders by the trailer, like this desk. Send the ship-to ZIP and the footprint and we size the load.
What is the minimum bulk order?
We state none, because there is no published offer sheet. Tell us the quantity and we answer with what applies.
Are wholesale plastic pallets cheaper?
We state no prices. Ask for a quote and we answer with the make, the ratings and the count to expect.
Ask for a load quote
The request ends here: we answer with the count that fits your footprint, and say where no maker publishes one.
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Last reviewed 2026-11-12.