How Close-Boarded Pallets Helped Pelgar International Reduce Product Damage in Global Exports

Client: Pelgar International
Supplier: Associated Pallets

Customer Overview

Pelgar International is a leading supplier of professional pest control products, serving customers across the Americas, Australasia, Asia and Africa. Many of their products are supplied in durable plastic buckets, chosen for their practicality, ease of handling and ability to maintain product freshness throughout storage and use.

As part of the company’s ongoing sustainability programme, Pelgar introduced recycled content into the manufacture of its plastic buckets, thereby reducing environmental impact and supporting broader sustainability goals.

The Challenge

Following the introduction of recycled materials, Pelgar identified an unforeseen issue within its export supply chain. Although the updated buckets continued to perform effectively in normal use, the revised material composition slightly reduced their structural strength. During international shipments, buckets positioned on the bottom layer of palletised loads were occasionally collapsing under load.

The issue was traced to gaps within standard pallet deck boards, which created pressure points beneath the buckets during transport.

The Solution

Working closely with Pelgar’s team, Associated Pallets evaluated several potential solutions, including the use of layer boards and alternative pallet configurations. Following a series of shipping trials conducted in August 2024, close-boarded pallets were identified as the most effective solution.

Unlike standard pallets, close-boarded pallets eliminate the gaps between deck boards, creating a continuous support surface beneath the load.

The Results

The implementation of close-boarded pallets delivered immediate and measurable improvements, including reduced product damage, fewer customer complaints, improved shipping confidence and protection of Pelgar’s brand reputation.

Today, Pelgar International uses more than 300 close-boarded pallets every month to support global exports.

Customer Testimonial

“Thank you to Associated Pallets for helping us reduce damage and improve customer perception of our quality.”

Conclusion

Through collaborative problem-solving and rigorous testing, Associated Pallets delivered a solution that enabled Pelgar International to reduce transit damage, maintain efficient export operations and continue supporting its sustainability goals with confidence.