06/16/2026
5% of the cost. 50% of the strength.
That's the math on the most overlooked part of pallet manufacturing.
Not the lumber. Not the deck boards. Not the design.
The nails.
Stefan recently took a class at Virginia Tech's Center for Packaging and Unit Load Design — one of the only programs in the country dedicated to the engineering behind pallets — and this was the number that stuck with him.
Fasteners are roughly 5% of what a pallet costs to build. They're responsible for about 50% of its structural strength.
Think about that the next time a load shifts in transit or a pallet fails mid-stack.
The wood gets the blame. The story is almost always in the joinery — shank diameter, coating, holding power, whether the nail was matched to the species of wood it was driven into.
This is also where PDS — the Pallet Design System developed at Virginia Tech — earns its keep. Instead of guessing at specs, PDS lets pallet manufacturers engineer a pallet for the actual load it will carry, the actual environment it will live in, and the actual handling it will take.
It's the kind of detail that separates a pallet supplier from a pallet partner. And it's the reason the customers we work with across Michigan, Indiana, and Illinois keep coming back load after load — because the engineering matches the promise.
A pallet is only as strong as the smallest decision made during its build.