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1. High pressure injection molding
The injection molding machine includes a heated barrel with a rotating screw. Virgin plastic and colorant are melted together in a bucket. The molten plastic is then injected into the molds that are clamped together, and pressure is applied. Injection and clamping forces are very high. Copolymer polypropylene or high density polyethylene resins are often used for injection molding trays. The cost of high-pressure injection molds is quite high, but the process has fast cycle times. High pressure can also create pallets or other products with detailed features.
2. Structural foam molding
Structural foam molding is a form of low pressure injection molding. The mold cavity is filled with polyethylene or polypropylene plastic pellets and nitrogen. Heat activates the foaming agent, which in turn produces a nucleus with a solid outer skin. This method requires less raw material and also produces plastics with higher strength-to-weight ratios. The mold itself is less expensive than the mold used for high pressure injection molding.
3. Compression molding
Compression molding is another tried and true method for making plastic and molded pallets made from other materials such as wood chips and resins. Two-piece dies are loaded with material manually, mechanically or through an extruder. Once loaded, the pressure forces the mold to close, and the pressure forces the material to fill the mold cavity. In the compression molding process, many different types of recycled materials are used, including various plastics, rubber, synthetic resins, and other recycled waste.
4. Profile extrusion
Profile extruded pallets look very similar to wooden pallets and are constructed in a similar manner. The raw material is melted and forced through an extruder. After cooling, the extruded material is cut to wood-like dimensions and secured with nails, screws, glue or heat welding. Industrial regrind and post-consumer recycled materials can be used to reduce costs, and the addition of wood fibers or other materials to extruded profiles can increase stiffness and help reduce .
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