What To Do With a Broken Pallet
Broken Pallet Upcycling
Pallets are the backbone of supply chains around the world, and while they’re built to be durable, even the toughest pallet can break down over time. When that happens, what you do next matters. Tossing broken pallets into a dumpster might seem like the easiest solution, but it can be wasteful, costly, and bad for the environment.
At Olympic Forest Products, we believe that a broken pallet doesn’t have to be the end of the line. With the right approach, these materials can be repaired, recovered, or recycled—keeping your operation running efficiently and sustainably.
How to Know If a Broken Pallet Is Beyond Repair
Not all pallets are created equal — and not all damage is worth repairing. Knowing when a pallet has reached the end of its life cycle is essential for keeping your operations safe, efficient, and cost-effective.
A pallet is typically considered beyond repair when:
Multiple stringers are cracked or broken – especially if they’ve already been previously repaired. Repetitive damage weakens the structural integrity, posing safety risks in transport or warehouse handling.
Severe warping or water damage is present, making the pallet unstable or unusable for stacking. Warped pallets can shift loads and lead to product loss or equipment malfunctions.
Excessive missing or splintered deck boards – if replacing over 30-40% of the boards is required, it may no longer be cost-effective to fix.
Infestation or mold is visible, which disqualifies the pallet from reuse in most regulated industries like food, pharmaceuticals, or international shipping.
Damage impacts safety – if a pallet poses a risk to workers, it should be removed from rotation, regardless of its material cost.
CALLOUT BOX: “We always begin with a full inspection. If a pallet can be safely repaired and put back into rotation, we’ll do it. But if it compromises safety or efficiency, it gets pulled from the system,” says Brock Riemenschneider, Pallet Design Engineer at Olympic Forest Products.
At Olympic, we don’t just throw broken pallets into the scrap pile. We salvage usable components and responsibly recycle what’s left — ensuring your business stays sustainable and compliant while minimizing waste.
4 Important Steps in Evaluating Your Broken Pallet
Before you toss a broken pallet aside, it’s important to determine whether it still has value—either as a repairable asset or a recyclable material. Take a strategic approach to pallet recovery, evaluating every broken pallet for its repair potential, parts recovery, or recycling options.
Here are four key steps that guide our process and help businesses make the most of their pallet inventory (and save you money in the process!):
Step 1: Assess the Damage
The first step is understanding the condition of the broken pallet. Is it missing a deck board or two? Is the wood split or warped? Has it lost structural integrity entirely?
“We encourage our customers to think of pallets like any other asset,” said [Insert Name]. “Not every break is the same, and many can be fixed quickly and affordably.”
Standard 48x40-inch pallets are the most common candidates for repair and reuse because of their consistent demand. Larger or non-standard sizes can also be assessed for alternate uses.
Step 2: Consider Repair vs. Recovery
Once the pallet is assessed, the next step is determining whether it can be repaired or if it should be recovered for parts.
Repair: If the damage is minor, repairing the pallet can restore its function at a fraction of the cost of buying new. Olympic offers full-service pallet repair, keeping your inventory usable and your costs low.
Recovery: When repair isn’t economical, pallets can still serve a purpose.
CALLOUT BOX: “We salvage usable components from broken pallets to use in future repairs,” noted Brock Riemenschneider, Pallet Design Engineer at Olympic Forest Products. “Nothing goes to waste.”
Step 3: Recycle Responsibly
When a pallet is beyond repair or recovery, recycling is the next best option. Olympic Forest Products processes unusable wood into mulch, animal bedding, or biofuel. Recycling helps reduce landfill waste and supports a circular economy.
Step 4: Work With a Pallet Partner
One of the best ways to handle broken pallets is to prevent them from piling up in the first place. That’s where working with a dedicated pallet management partner like Olympic can make a big difference.
Through our closed-loop pallet repair and recovery system, we help businesses:
Monitor pallet quality
Reduce waste and disposal fees
Improve sustainability reporting
We collaborate directly with our customers to create tailored plans that ensure their pallets are being reused, repaired, or recycled efficiently.
Broken Pallet? Don’t Throw It Away.
Whether you’re managing a high-volume warehouse or overseeing logistics for a small operation, broken pallets are inevitable. But with a smart strategy in place, they don’t have to be a problem.
Upcycling Ideas for End-of-Life Pallets
Just because a pallet can’t be repaired for reuse in the supply chain doesn’t mean it’s headed for the landfill. Many companies — and even creative individuals — give old pallets a second life through upcycling.
Popular upcycling uses include:
Furniture building – Disassembled pallet wood can be turned into rustic coffee tables, shelving, or outdoor seating.
Gardening or farm projects – Pallet wood is ideal for raised garden beds, compost bins, or vertical planters. You can also break your pallets down into bedding for your garden, animal housing, or other uses.
Wall treatments or décor – The natural, weathered look of pallet wood adds charm to accent walls, signage, and custom displays.
Partner with a Team Who Recycles and Fixes Pallets
Not every broken pallet is destined for the landfill. At Olympic Forest Products, we evaluate each pallet to determine whether it can be safely and effectively repaired. If a pallet is beyond repair, we responsibly recycle the materials—salvaging usable components and reducing waste wherever possible.
Have broken pallets piling up?
Contact Olympic Forest Products to learn how our repair, recovery, and recycling services can help you reduce waste, save money, and support a more sustainable supply chain.
