With the output product being a durable molded plastic pallet, this line uses modern equipment, highly automated operation, energy saving and minimizing manual labor. In the following article, Intech Group will give you detailed information about a plastic pallet production line that helps bring outstanding economic efficiency to businesses in the plastic recycling and manufacturing industry.

Equipment used in the plastic pallet production line

A plastic pallet production line is made up of many modern equipment, operating continuously with high automation, ensuring stable production efficiency and output quality. Below are the main equipment in the line:

1. Input materials

The line can use raw materials such as crushed PP and PP film. Depending on the specific needs of the customer, the raw material supply plan will be selected corresponding to the properties and characteristics of each type of raw plastic.

2. Raw material supply and transportation system

Raw materials are transported to the forced feeder through an automatic roller conveyor system, ensuring a steady and even flow of raw materials for the next stages.

3. Raw material color sorting equipment

The line is equipped with a masterbatch device that allows the pallet color to be adjusted according to customer requirements. The color feeding speed can be programmed in the control program. If the color is not required, this device can be removed to optimize investment costs.

4. Plastic extruder

This is the core equipment of the line, the extruder uses a gear oil pump, operates smoothly, and has low noise. The control system uses PLC and Schneider electrical components, combined with a 132kW frequency converter for the main machine and an 11kW for the feeder, ensuring precise control of the plastic extrusion process.

5. Dosing tank

The line is equipped with two dosing tanks, a large tank that holds enough plastic for one pallet pressing, and a small tank that is an intermediate tank, ensuring that the raw material source is always ready. The molten plastic is fed into the mold through the nozzle, and then pressed into a pallet in the mold. The dosing tank system operates synchronously with the press.

6. Plastic pallet mold

The mold is made of P20 steel and 45 steel, with high durability, anti-rust, suitable for plastic molding process. Mold size: 1200×800 mm, weight 6 tons, can withstand more than 300,000 times of pressing. Mold guide helps to position accurately, ensuring consistent output pallet quality.

7. Plastic pallet press

The press is the core equipment, with a three-beam, four-column structure, maximum pressing force up to 1,000 tons, height 5 meters, weight 20 tons. Mold holding time is about 80 seconds (can be changed according to raw material type), working pressure 600–700 tons and modern servo motor control technology, smooth operation, using Siemens system and Schneider components.

The machine can flexibly change molds to produce many different pallet models from scrap plastic or virgin plastic.

8. Mold Cooler

Ensures the mold maintains a stable temperature of 40–50°C, supporting the pallet shaping process. The machine uses environmentally friendly R407C refrigerant, meeting European environmental protection standards, helping to maintain cooling efficiency and mold durability.

9. Loading and unloading robot

After the pallet is completed, the loading and unloading robot automatically performs the task of picking and moving the pallet to the storage or packaging location. This device helps optimize labor, increase speed and accuracy at the end of the line.

Detailed process of manufacturing plastic pallets according to factory standards

In a modern plastic pallet production line, each step in the process is optimized to ensure product quality according to factory standards. Below are 8 production steps commonly applied in large and professional factories:

1. Prepare raw materials

Use clean, sorted virgin HDPE, PP or recycled plastic. Raw materials must be dried to completely remove moisture before being put into the extruder, in compliance with ISO 15270 standards on processing and recycling industrial plastics.

2. Mold design and processing

The mold is made from hardened steel, similar to the material used in the steel billet casting production line, to ensure durability and high pressure resistance. The mold design must be precise, with integrated air vents and a circulating cooling system, ensuring sharp, even and sturdy pallet shaping.

3. Heating and melting plastic

Plastic raw materials are fed into the screw of the press, melted at a temperature of 180 - 250°C. The system needs to maintain a stable and evenly distributed temperature to avoid burning the plastic or creating air bubbles.

4. Molding to form the product

Molten plastic is injected into the mold at a high pressure of 500 - 1,200 tons, equivalent to the pressure in the metal casting process. The pressing cycle usually lasts 30 - 60 seconds, requiring the mold to be filled evenly so that the finished pallet does not have holes, cracks or deformities.

5. Cooling and demoulding

After pressing, the mold is cooled with water or cold air, helping the plastic to quickly take shape. When the temperature reaches a stable level, the pallet will be removed from the mold by a mechanical system or a supporting robot.

6. Product quality inspection

After molding, the product will be tested according to international standards such as ISO 8611 or ASTM D1185. The criteria include: impact resistance, static - dynamic load, warping resistance. Unqualified pallets will be classified for recycling.

7. Recycling surplus plastic

The burrs, surplus plastic or defective pallets will be crushed, screened and mixed with input materials. This process helps save materials and minimize waste, in line with the circular production trend.

8. Packaging and storage

After completion, plastic pallets are packaged in batches and stored on specialized shelves to avoid deformation. Modern factories can integrate QR codes or RFID chips on each pallet for easy traceability and more effective warehouse management.

Features of plastic pallet production line

- No need to wash or granulate. Can use recycled plastic directly, reducing 50% of raw material costs and simplifying the production process.

- Automatic operation system, reducing labor, consuming less electricity, environmentally friendly.

- Equipment price is significantly lower than traditional plastic injection systems, suitable for small and medium enterprises.

- Turn waste plastic into plastic pallets, contributing to reducing pollution and moving towards sustainable production.

- Solid, durable finished pallets, saving 60% of storage space compared to traditional pallets.

Common mistakes in plastic pallet production

During the operation of the plastic pallet production line, if each stage is not well controlled, businesses can easily encounter errors that affect the quality and production costs. Here are some common mistakes to avoid:

Choosing the wrong type of input plastic: Using poor quality recycled plastic for pallets that require high loads can easily cause the product to crack, become brittle or break when used.

Worn or damaged molds; Not periodically checking the molds leads to distorted products, incorrect sizes, and large burrs that affect aesthetics and durability.

Incorrect adjustment of mold parameters: Incorrect setting of pressure or mold speed causes uneven distribution of plastic, causing warping or weak structure.

Ignoring the quality inspection step: Not checking the load and stability of each batch of products before leaving the factory increases the risk of defective products, affecting reputation and incurring warranty costs.

Plastic pallet production line installed by Intech Group

With more than 14 years of experience in providing automation solutions, conveyors, conveyor belts, industrial robots, Intech Group has affirmed its capacity to deploy modern production lines for many large factories at home and abroad.

Intech Group has successfully installed a plastic pallet production line at a large factory in Hai Duong. The entire plastic pallet production line is synchronized, automatically controlled by PLC, helping to optimize performance, save labor and significantly reduce production costs. This is an ideal solution for businesses aiming for automation in the manufacturing industry. Contact Intech Group now for quick support and advice.