A method of assembling a pallet using a machine includes folding a first portion of a pallet support column to define a vertical support structure. The method further includes folding a second portion of the pallet support column to engage the vertical support structure. The method further includes gluing at least a portion of the second portion to the first portion. The method further includes coupling the pallet support column to at least one of a bottom member or a top member of the pallet.

Exemplary embodiments of a multi-layer composite pulp product comprise one or more pulp layers, and one or more reinforcement layers disposed therebetween. Each of these layers preferably include a respective pattern of opposingly-defined cavities and protrusions, wherein the mutual disposition of the layers results in their patterns axially aligning with one another. The reinforcement layers may be comprised of a recycled plastic, a metallic mesh or a metallic sheet. One example process for manufacturing a multi-layer composite pulp product may comprise fabricating a reinforcement layer, forming a soggy first pulp layer, placing a reinforcement layer on the soggy first pulp layer, forming a soggy second pulp layer, and positioning the soggy second pulp layer on the reinforcement layer. A precursor wet composite may thereby be formed, and may be dried at a selected heating temperature and under a selected pressure.

A household packaging assembly includes a paper-based packaging container extending in the vertical direction between a bottom and a top. The paper-based packaging container defines a container interior for positioning a household appliance therein and a container exterior. Additionally, the packaging assembly includes a household appliance positioned within the paper-based packaging container and a paper-based skid base attached to a bottom of the paper-based packaging container for supporting the paper-based packaging container. The paper-based skid base includes a plurality of paper-based boards extending across a bottom of the paper-based packaging container in the transverse direction and spaced apart from each other in the lateral direction. Furthermore, a lifting fork aperture is defined between each adjacent pair of paper-based boards of the plurality of paper-based boards for receiving one or more lifting fork extensions therethrough for lifting the household appliance packaging assembly.

The present invention relates to a waterproof paper-based pallet having a paper pallet body, the paper pallet body comprising a paper panel having a load-bearing upper side and paper legs connected to the paper panel. The essence of the invention is that the paper pallet body has a spray-formed coating of a solvent-free polyurethane system, a polyurea system or a hybrid polyurea system around its entire outer surface. The invention also relates to a method of producing such a paper-based pallet.