Pallet Quality Sorting A B & Broken Core
Standardized procedure for inspecting and categorizing pallets into A-grade (no repair), B-grade (minor damage, repairable), and broken/core (unusable) categories. Ensures consistent quality for outgoing shipments, efficient repair workflows, and safe disposal of damaged units.
To establish uniform criteria for sorting wooden pallets into A-grade (ready for shipment), B-grade (requiring minor repair), and broken/core (scrap/recycling). Proper sorting reduces customer returns, streamlines repair labour, and prevents unsafe pallets from entering the supply chain.
This SOP applies to all inbound and outbound pallet sorting stations in dry storage warehouses, distribution centres, and pallet repair facilities. It covers visual inspection, dimensional verification, grade marking with coloured paint, and segregation into designated holding areas. Excludes plastic/metal pallets and pallets intended for export quarantine treatment.
- Lockout/tagout all conveyor belts, pallet jacks, or forklifts before handling pallets in the sorting zone. Verify zero energy state.
- Mandatory hard hat, safety glasses, steel-toe boots, and cut-resistant gloves. High-visibility vest required within 5 m of forklift traffic.
- Watch for protruding nails, loose boards, and splinters. Never carry a pallet on edge; use two-person lift for oversized units.
- Spray paint cans (blue, green, red) — solvent-based weatherproof
- Pallet jack or forklift with fork extensions
- Pallet inspection gauge (for crack width/depth)
- Hammer and nail puller for minor protrusions
- Measuring tape (metric and imperial)
- Clipboard and pallet log sheet (or tablet with SupplyGrid mobile app)
Apply lockout/tagout to all conveyor systems and pallet handling equipment in the sorting zone. Verify area is clear of debris. All personnel must wear required PPE.
Visually examine for broken stringers, missing deck boards, protruding nails, moisture damage, or insect infestation. Measure overall dimensions (standard 40×48 in / 1016×1219 mm). Flag odd sizes on log sheet.
Passes if: all deck boards intact, cracks ≤ ¼″ width, splits ≤ 6″ length, stringers solid, no protruding nails, no rot or insect damage. Spray blue paint on top-left stringer. Move to A‑grade staging.
Qualifies if: missing ≤ 1 deck board, cracks ≤ ½″, stringer damage that can be sistered, or ≤ 3 protruding nails that can be hammered down. Spray green paint. Set aside for repair station.
Assigned if: missing ≥ 2 deck boards, stringer broken through, fire damage, chemical stains, or warp > 2″ diagonal. Spray red paint. Stack in designated scrap bin.
Count and record each grade daily on the pallet log sheet (or SupplyGrid mobile app). Move A‑grade to shipping, B‑grade to repair queue, broken to recycling. Ensure all marks visible. Return tools and de‑energize equipment.