European Major Logistics Group

1200×1000mm heavy-duty cross-deck plastic pallet mold project

PAIN POINTS

The original pallets showed significant creep deflection in the central area under long-term rack loading, causing AS/RS handling errors. Uneven mold cooling caused sink marks at rib roots, reducing load-bearing life.

MOTEK SOLUTION

• Used FEA to optimize rib layout and wall thickness gradient for improved rigidity.
• Designed zoned independent cooling channels to eliminate rib-root sink marks, reducing cooling time by 28%.
• Used 2738 pre-hardened steel with precision guiding for deformation-free operation under high clamping pressure.

"motek's pallet mold improved our AS/RS efficiency by 30% and more than doubled pallet service life."

North American Pallet Rental Provider

1100×1100mm 9-leg lightweight export pallet mold project

PAIN POINTS

Export pallets require both lightweight design and load capacity. The old mold produced pallets that were too heavy, driving up sea freight costs. The 9-leg structure was difficult to eject, causing leg scuffing and stress whitening.

MOTEK SOLUTION

• Applied gas-assisted injection and local thinning to reduce weight by 18% while maintaining load capacity.
• Optimized leg draft angles and ejection system to eliminate scuffing and whitening defects.
• 2-cavity hot runner design with quick mold change system for flexible multi-variant production.

"motek helped us achieve our pallet lightweighting goal, saving over $200,000 annually in sea freight."