Four-Way Entry Leg-Supported Large Blow-Molded Pallet Mold — Product Introduction (Motek Pallet Mold Series)
Four-Way Entry Leg-Supported Large Blow-Molded Pallet Mold — Product Introduction (Motek Pallet Mold Series)
Product Positioning
Motek introduces dedicated blow mold solutions for four-way entry, leg-supported large blow-molded pallets. These pallets feature large decks, integrated bottom support legs, and a four-way forklift entry design, formed integrally through the hollow blow molding process. Four-way entry greatly enhances forklift operation flexibility, while bottom legs provide higher ground clearance and stronger load-bearing support, making them widely suitable for automated storage and retrieval systems (AS/RS), large logistics centers, cold-chain warehousing, and heavy cargo turnover. The core challenges in mold development lie in uniform blow-forming of the large parison across complex leg structures, precision forming of entry openings in all four directions, and mold clamping precision and cooling efficiency control for ultra-large molds (supporting maximum sizes up to the 1600×1600mm class).
Core Specifications
| Item | Specification |
|---|---|
| Applicable Plastics | HDPE (High-Density Polyethylene, low-temperature resistant, high impact resistance, preferred for blow molding) |
| Mold Material | P20 / 718H (pre-hardened steel), surface hardness up to HV800–1000 after nitriding; high-strength forged steel mold base recommended for ultra-large molds |
| Number of Cavities | 1×1 (single cavity for large blow-molded parts) |
| Molding Process | Hollow blow molding (extrusion blow molding), parison inflation forming |
| Entry Method | Four-way entry (insertion from both long and short sides) |
| Applicable Specifications | 1400×1200mm, 1500×1300mm, 1600×1400mm, 1600×1600mm (maximum square size), etc. |
| Load Capacity Reference | Dynamic load 1.5–2 tons / Static load 5–8 tons (depending on specific leg layout and wall thickness design; the 1600 square specification offers greater load-bearing potential) |
| Cooling System | Conformal/zoned cooling channels + targeted heat dissipation around legs and entry openings |
| Demolding Method | Blow mold opens for removal, coordinated with pneumatic/mechanical assisted demolding mechanisms |
Product Features
Uniform Blow-Forming and Leg Formation of Ultra-Large Parison.
Four-way entry large pallets (especially the 1600×1600mm ultra-large square structure) have large areas, long diagonals, and widely distributed legs. The melt parison must extend to all corners during inflation. Motek uses blow molding simulation software to optimize the initial parison dimensions and wall thickness distribution, ensuring that after inflation, the center and edges of the large deck as well as each bottom leg achieve uniform wall thickness, avoiding local thin spots that cause load-bearing collapse.
Precision Forming and Structural Reinforcement of Four-Way Entry Openings.
Four-way entry requires standard forklift openings on all four edges of the pallet. Motek combines the entry openings with the bottom leg structure in mold design, forming them through sliders or precision inserts. The top of the entry openings requires sufficient material thickness to resist friction and impact during fork insertion. Opening edges are chamfered and rounded to prevent fork scratching.
Clamping Precision and Rigidity Assurance of Ultra-Large Molds.
The 1600×1600mm class square mold is an ultra-large mold, and force-induced deformation during clamping is a process challenge. Motek adopts a high-strength forged steel mold base equipped with heavy-duty guide pins, guide bushings, and precision center locating blocks. This ensures that upper and lower cavities and lateral sliders engage precisely during clamping, minimizing flash and ensuring pallet appearance quality and dimensional consistency.
Cooling and Deformation Control in Deep Leg Cavities.
Leg areas have relatively thick walls, and heat concentrates internally after blow molding, resulting in slow cooling. Uneven cooling can easily cause warpage in large-span pallets after demolding. Motek designs high-thermal-conductivity inserts or conformal cooling channels inside the legs and at the tops of entry openings to focus heat dissipation from leg areas. Meanwhile, cooling water layout on both mold walls is optimized to synchronize upper and lower surface cooling, maintaining dimensional stability of the ultra-large deck.
Automated Warehousing Compatibility and Load-Bearing Rigidity.
Large four-way entry pallets are often used in automated AS/RS, where dimensional standardization and bottom ground clearance are critical. Bottom legs and entry openings must interface perfectly with roller conveyors and stacker cranes. Motek designs reinforced rib transitions at leg-to-deck connections, ensuring that under full-load conditions of 1.5–2 tons dynamic load, long-term high-frequency turnover does not cause leg fracture or deck sinking.
Surface Anti-Slip and Logo Customization.
Large pallets carry heavy cargo, making surface anti-slip textures critical. Motek etches deeper anti-slip patterns on the cavity deck area to increase friction; meanwhile, brand logos, size markings, or QR code engravings are customized in non-load-bearing areas to facilitate customer asset tracking and management.
Applicable Specifications Reference
| Pallet Specification (mm) | Structure Type | Load Reference | Entry Method | Application Scenarios |
|---|---|---|---|---|
| 1400×1200×150 | Double-face with legs | Dynamic 1.5T / Static 5T | Four-way entry | Large warehousing, home appliance logistics |
| 1500×1300×150 | Double-face with legs | Dynamic 2T / Static 6T | Four-way entry | Automated AS/RS |
| 1600×1400×150 | Double-face with legs | Depends on wall thickness and design | Four-way entry | Heavy industry, bulk cargo turnover |
| 1600×1600×150 | Ultra-large square with legs | High load (depends on wall thickness design) | Four-way entry | Ultra-large equipment, special logistics consolidation |
Applications
Motek four-way entry leg-supported large blow-molded pallet molds are suitable for:
- Large blow-molded pallets dedicated to automated storage and retrieval systems (AS/RS)
- Four-way entry dunnage pallets for large logistics sorting centers
- Heavy-duty turnover pallets for home appliance/auto parts industries
- Ultra-large equipment/special cargo consolidation (1600×1600 specification)
- Large blow-molded pallets for export containers
- Heavy-duty blow-molded pallets for cold-chain logistics
Service Process
After the customer provides 3D product drawings, specific dimensions (supporting maximum 1600×1600mm), load requirements (dynamic/static), and blow molding machine model, Motek completes blow molding simulation (including parison size evaluation, large-face and leg wall thickness distribution prediction, and cooling optimization) and mold structure confirmation; cavity steel uses P20/718H with nitriding treatment, and ultra-large specification molds use heavy-duty steel frames; progress and key milestones are regularly reported during processing. During trial molding, Motek cooperates with the customer's large blow molding machine for parison adjustment, inflation parameter optimization, and full-size wall thickness inspection, with emphasis on verifying four-way entry opening precision, leg forming completeness, and ultra-large deck flatness. Before shipment, molds undergo anti-rust treatment and action testing, with water circuit diagrams, consumable parts lists, and large-scale blow molding process parameter recommendations provided. Technical support is available during the warranty period, with lifetime maintenance consultation.
Motek — From standard double-face blow molding to four-way entry heavy-duty blow molding, supporting maximum 1600×1600mm ultra-large specifications, providing high-rigidity, high-precision mold solutions for large logistics and warehousing pallets.
