When a pallet comes back from a shipment with a broken board or a cracked stringer, the instinct at many businesses is to toss it and grab a new one. That instinct is costing them money — a lot of money. Here's why pallet repair should be your default approach.
The Numbers
A new GMA 48x40 pallet costs $11-20 depending on wood species and construction quality. A Grade A recycled replacement costs $5-10. But repairing a pallet with a broken board? That typically costs $2-5 in labor and materials, including the replacement board, nails, and labor.
For a business going through 500 pallets per month with a 20% damage rate, the math is compelling. Replacing 100 damaged pallets per month with new ones costs $1,100-2,000. Repairing those same pallets costs $200-500. That's $800-1,500 in savings per month, or $9,600-18,000 per year.
What Can Be Repaired
The vast majority of pallet damage is repairable. Broken deck boards (top or bottom) — the most common damage — are simply removed and replaced. Cracked stringers can be reinforced with sister boards (a new board attached alongside the cracked one). Protruding or missing nails are reset or replaced. Even significant damage affecting multiple boards can often be repaired for less than 60% of replacement cost.
When to Replace Instead
Repair isn't always the answer. Replace rather than repair when the repair cost would exceed 60% of the replacement cost, when more than half the boards need replacement, when stringers or blocks are severely rotted, when mold or contamination cannot be remediated, or when the pallet has been recalled or flagged for safety reasons.
DIY vs. Professional Repair
Some businesses maintain in-house pallet repair capabilities. This makes sense for large-volume operations that damage pallets frequently. For most businesses, outsourcing repair to a specialist like Sacramento Pallet Co. is more cost-effective — we have the equipment, materials, and skilled technicians to repair pallets efficiently.
Our Repair Program
We offer both on-site and facility-based repair services. For high-volume clients, we can set up a regular pickup and repair schedule — we collect your damaged pallets, repair them at our facility, and return them ready to use. Contact us to discuss a repair program tailored to your operation.