How Thermofusion™ Technology Creates Durable, High-Performance Pallets

During the use and transportation of pallets, it’s common to encounter problems like damaged, broken or unusable pallets. When your business relies on the performance of these pallets, poor quality and damaged structure can impact the durability that you’re expecting. The short shelf-life of these pallets means that you’re responsible for their disposal. With the material deteriorated, they won’t be fit for repurposing, so they inevitably contribute to waste. 

At Re>Pal, we haven’t just improved the material of the pallets your business relies on, but we’ve considered and improved the quality, too. We use recycled plastic pallets, ensuring that when you’re done with them, they can be repurposed. However, our Thermofusion technology ensures that they perform exactly as needed. 

For durable and high-performing pallets, Re>Pal have thought of everything. Don’t believe us? We’ll break it down. 

Our Pallet Composition

We’re committed to a 100% sustainable approach, which is why our pallets are made using 100% recycled plastics. Whether it came from post-consumer waste or industrial waste, we’ll make sure it’s repurposed into the pallets you need. The best part? When you’re done with them, they won’t be filtered into waste like you’d expect. We’ll repurpose them all over again. 

As a material, plastic is strong, and our Thermofusion technology ensures that it stays that way. 

Thermofusion™ Technology: Everything You Need To Know

Our Thermofusion technology is designed to extend our recycled plastics capabilities so your pallets perform how you need them to. Durable, high-performing and reliable, that’s what our thermofusion technology offers your business. So, how does it work? 

1. Preparation: The cleaned and dry plastic waste is shredded into small flakes, which increases the surface area in preparation for melting. The flakes from a range of different  types of polymers are selected and blended to ensure the durability and robust performance from the pallet once formed in our proprietary mold designs.

2. Thermo/ Heat: During the thermo step, the plastic flakes are heated until they become molten. This is done in a controlled environment until the plastic is a homogenous type of ‘dough’. So the plastic isn’t just melted, but it is specifically prepared to bond with the polymers. 

3. Fusion/ Pressure: The molten plastic is then transferred into a high-pressure and custom-made mould. The pressure forces the plastic polymers to fuse at a molecular level, so that they become consistent and void of any weak points. 

4. Solidifying: This step is where the fused plastic cools under pressure and becomes a singular dense pallet. 

Thermofusion is the process by which the plastic becomes an entirely merged piece. In timber pallets, for instance, the pieces are nailed together to make a pallet. However, our process ensures that the plastic pallet is fused which ensures there are no weak points that can become damaged over time. 

Why Thermofusion™ Technology Is The Way Forward

Now that the thermofusion process is clear, you might be wondering what the stand-out benefits are in comparison to your ‘traditional’ timber pallet creation process. Our Thermofusion technology provides you with the following benefits: 

Durability

As the process forms a one-piece pallet, there are no weak points such as nails, screws or splinters. It is built to last and withstand force and impact.

Performance

The fusion process creates a non-porous surface, which protects the pallet from moisture, oils, acids and alkalis. It is easy to clean and maintain, making it especially useful for food and pharmaceutical industries.

Strength and Weight

The pallet is created to be dense and structurally strong. So, our pallets offer dynamic load capacities, which provide product safety during transit and stacking operations.

Automation-Ready

Each one of our recycled plastic pallets is moulded to exact specifications, so the consistent weight and dimensions of our pallets are something you can rely on to facilitate your warehouse operations. 

FAQ’s

Are 100% recycled pallets hygienic?

The thermofusion process involves high heat and pressure, which creates a non-porous and solid pallet. As it doesn’t absorb moisture and contaminants in the same way as timber, it can be easily washed and sterilised to meet your demands. 

What happens when I’m done with the pallet if it doesn’t go to waste?

We’re proud to have a cyclical lifecycle for our recycled plastics, and this includes our pallets. When you no longer need them, you can return them to us, and we’ll grind them down and restart the thermofusion process to create new, high-performing pallets. Our pallets never have to end up in waste or landfills.

How does the long-term cost compare to a wooden pallet?

Our pallets are built for longevity and durability. The real cost-efficiency is in how little you need to replace and repurchase our pallets. Wooden pallets typically require 5-10 replacements in the same lifespan as one of our Re>Pal pallets. 

Re>Pal: Pallets and A Process

We’ve revolutionised more than just the pallet industry. Our pallets are built to be recycled, durable and high-performing. But it’s our thermofusion technology and process that really makes the difference. We’ve considered what your business needs from its pallets to bring you an alternative that is not only long-lasting, but it saves the environment at the same time. 

You don’t need to replace your broken pallets and contribute to waste. All you need is Re>Pal pallets that are stronger, smarter and more sustainable. Contact our team directly on WhatsApp at +62343740100 or send us an email at infore-pal.com.