Pallets are at the core of product movement across the supply chain. Every shipment, every transfer, and nearly every warehouse operation relies on them. But once those pallets have fulfilled their initial purpose, what happens next can either support your operations—or slow them down.
That’s where pallet sorting comes in.
It’s one of the most important, yet often overlooked, components of an efficient supply chain. Done properly, sorting helps reduce operational waste, recover asset value, and improve overall flow. Relogistics specializes in providing professional pallet sorting services that allow companies to streamline operations and focus on what matters most—their core business.
Why Sorting Matters
A leading national retailer with more than 25 e-commerce fulfillment centers experienced firsthand what happens when pallet management is not handled efficiently. Attempting to manage the process internally, the company struggled with labor shortages, limited oversight, and inconsistent training. Sorting accuracy was a problem, and they lacked the reporting systems to monitor what was happening across their network.
Relogistics stepped in to help. By building a customized on-site pallet program—including trained personnel, equipment, sorting processes, and accurate reporting—we helped the retailer eliminate inefficiencies, reclaim pallet value, and generate $2.7 million in savings.
Their experience is just one example of how professional pallet sorting delivers measurable value. See how we did it.
What Is Pallet Sorting
Pallet sorting involves inspecting and separating used pallets by type, size, and condition. It’s a critical first step in determining whether a pallet can be reused, repaired, or repurposed.
Relogistics offers both on-site and off-site sorting services:
- On-site sorting is conducted directly at the customer’s distribution center, which enables immediate reuse and reduces transportation needs.
- Off-site sorting is completed at Relogistics Reusable Asset Depots (RADs) and is ideal for more centralized or distributed operations.
Both approaches are supported by trained personnel and proven processes, ensuring that every pallet is managed correctly from the moment it’s received.
Grading and Classification
Not all pallets are created equal. Some are immediately reusable, while others need repair. Others are beyond reuse but still valuable when recycled into other products. Sorting by grade ensures you get the most out of every pallet.
Relogistics uses a standard grading system to classify pallets into three main categories:
- GMA 48x40 pallets, which are in high demand and often require little to no repair
- Repairable pallets, which are evaluated and rebuilt to extend their lifecycle
- Scrap pallets, which are responsibly repurposed into mulch, fuel, or other byproducts
Each load is tracked using pre-printed grade sheets, giving your team consistency and insight across locations. Our customers receive real-time access to data through our pallet tracking software, which helps with inventory planning and cost control.
How Pallet Sorting Improves Operations
Sorting creates structure and clarity within your supply chain. Reusable pallets are returned to circulation more quickly, and those that need repairs are flagged immediately. Damaged or unsafe pallets are removed before they cause issues.
This process supports:
- Faster warehouse throughput
- Fewer pallet purchases
- Less operational downtime
- Improved safety and storage optimization
By implementing a reliable pallet sorting program, companies not only reduce costs—they improve workflow and reduce risk across their distribution networks.
On-Site and Off-Site Sorting Options
Relogistics helps you determine the best sorting model for your operation. On-site sorting is ideal for larger facilities where quick reuse is critical, while off-site programs may be better suited for lower-volume or more distributed operations.
Both options offer the same advantages: accurate classification, labor efficiency, and reduced reliance on new pallet purchases.
Visibility Through Reporting and Technology
Relogistics provides full transparency into every pallet sorted, repaired, or removed from your facility. Our online pallet tracking software gives you access to comprehensive metrics, including daily activity reports and monthly summaries.
We only bill for the services we provide, and we compensate customers for surplus pallets removed from their facilities. This commitment to transparency allows operations leaders to make data-backed decisions with confidence.
Supporting Sustainability
Pallet sorting is not just good for business- it’s also good for the environment. By extending the life of pallets and reducing unnecessary waste, sorting helps you meet sustainability goals while keeping reusable materials in circulation.
This supports:
- Reduced landfill usage
- Lower emissions from new pallet production
- Corporate environmental and ESG initiatives
Relogistics helps customers build more sustainable operations by keeping usable pallets in play and reducing overall environmental impact.
Why Outsourcing Sorting Is a Smarter Move
While managing pallet sorting in-house might seem more cost-effective, it often leads to challenges. Labor management, equipment investment, compliance, and training all require time and resources. These tasks can quickly become a distraction from your core business.
Outsourcing to a trusted partner like Relogistics means you gain access to experienced teams, efficient systems, and data-driven insights—without the overhead. Our job is to handle pallet sorting with speed, accuracy, and accountability so you don’t have to.
Customized Solutions for Your Operations
Relogistics builds pallet sorting programs that align with your warehouse layout, inventory flow, and long-term goals. Our solutions are built around your needs, and they often include:
- Equipment and space planning
- On-site or off-site sorting and repair
- Program training and management
- Detailed tracking and reporting
We work closely with your operations team to ensure that the sorting process fits seamlessly into your daily workflow.
Conclusion
Pallet sorting is a fundamental part of supply chain efficiency. It may happen behind the scenes, but the results are visible across your operation- from cost savings and smoother logistics to improved sustainability and better asset management.
Relogistics provides professional, scalable pallet sorting programs that help companies like yours operate more efficiently and more effectively. Whether you need an on-site team or an off-site solution, our programs are built to match your supply chain and your goals.
Ready to improve your pallet sorting process? Contact Relogistics today to get started.