It all started with a handmade sign at the end of a long farm driveway.
“We buy any pallets,” the sign proclaimed proudly, marking the beginning of a 30-year journey for brothers Simon and Michael Kelly. Today, they are co-CEOs of one of the UK’s leading independent pallet businesses, Junction 4 Pallets (J4P).
“In many ways, the pallet business was a farm diversification project that took off,” Michael Kelly recalled. “In the early days, we used the farmyard, farm equipment, including a tractor with lifting forks on the back to move pallets. Farming in a true sense is marketing your own produce and managing your assets to maximize their potential, which is not that far removed from what we do with the pallets today.”
Agriculture remains a key market for J4P, but more regarding pallets for processed or milled crops such as those used by the brewing and distilling sectors. J4P offers comprehensive pallet recovery, reconditioning, manufacturing, and management services to major retailers and industrial clients.
The Kellys have developed J4P into a multi-site pallet manufacturer and recycler with facilities across the UK and Europe. And the company has answered recent labor shortfalls by looking to automation to make workers more efficient while reducing the strain on them.
Europe. J4P is a hub-and-spoke network operation with its major centers in Doncaster and Coventry.
What’s in a Name? Strategic Location and Expansion
Junction 4 Pallets offers end-to-end pallet solutions, including new and reconditioned UK standard (1200×1000) and Euro/EPAL (1200×800) pallets, not to mention two-way-entry and custom designs. Additionally, the company provides pallet collection, ISPM-15 heat treatment, EPAL-certified repairs, asset management, pallet storage, plastic pallet washing and wood waste grinding.
When I heard the company’s catchy name, Junction 4 Pallets, I assumed it was shorthand for Junction for Pallets, but I was assured that this was not the case. Instead, it is a nod to geography. The original Doncaster location is located strategically near Junction 4 of the M18 motorway.
“We’re not creative types,” laughed Simon Kelly, when asked about the story behind the company name, “But we are located just off Junction 4 of the M18 motorway. It’s a strategic location for transport and logistics, which are at the heart of what we do.”
“Doncaster is also ideally placed to bring in timber through the Humber ports,” added Michael. “It’s halfway between Edinburgh and London, so it sits right on the national road distribution network.”
These days, J4P is a hub-and-spoke network operation with its major centers in Doncaster and Coventry. These hubs are supplemented by satellite and service locations that help manage collection, sorting, repair and delivery across a wide geographic area. The company has many clients in the brick-and-mortar retail sector and ecommerce.
“Our hubs do the heavy lifting,” explained Simon. “That’s where we handle manufacturing, repair and sortation, heat treatment, and plastic pallet washing. Satellites act as staging posts, improving transport efficiency. Service sites, meanwhile, are located on customer premises and focus on sorting, repairing and storing customer-owned equipment.”
A Changing UK Market, Recruitment Challenges
The UK market differs in several important ways from North America. One major distinction is the convergence of international pallet flows. “We are quite unique in that we are an island and a convergence point for trade,” said Michael. “You see US pallets, Euro pallets, and UK standards. We have to be able to deal with all of them.”
Brexit has added to the complexity, impacting inbound pallet throughput from the continent, changing heat treatment requirements, and dramatically restricting labor availability. “We’ve seen a reduction in European pallet flows,” said Simon. “That’s changed our mix between the Euro 800×1200 and UK standard 1200×1000 pallets.
“As well,” he added, “we now must heat treat everything for export into the EU, per ISPM-15.” The proportion of pallets processed at J4P is about 75% UK standard and 25% Euro, with a sprinkling of GMA-style pallets. There are customers for even the modest volumes of 48×40-inch pallets recovered.
As mentioned above, Brexit threw a wrench into labor recruitment. “We’ve now got a smaller pool to recruit from,” Simon noted. “Before, we had access to workers from across the European Union. Many of them had strong skillsets in our sector. Now we have to train people up from scratch.”
“We’ve put major focus on training and retention,” he added. “The skillset we need isn’t widely available anymore, so we’re building it ourselves.”
Pallet Recycling Powered by Automated Sort and Repair Lines
“You’ve got to take a holistic approach to timber packaging,” Simon said, explaining J4P’s perspective on being a full-service provider. “There’s the new sector, the reused sector, and the recycled part of it. All three have to come together to deliver the right solution to customers.”
J4P’s reconditioning process relies on automated sortation and repair lines from Netherlands-based Pallet Sorting Systems (PSS). In North America, PSS equipment is represented in a reciprocal relationship with Automated Machine Systems (AMS). AMS handles the sales consultation and installation process in this region of the globe.
For more information, see the ad on page 43 or call (877) 267-8384. Or in other parts of the world, visit https://www.palletsortingsystems.nl/en/.
Each of J4P’s hub locations—Doncaster and Coventry—features an identical PSS line. The most recent installation was at Coventry in 2024. These lines are constructed from standardized, modular components, allowing them to accommodate the wide variety of UK pallet formats without modification.
Pallets are inducted into the system via an extended infeed with a tipper and buffer, ensuring continuous flow and eliminating wait time for the sorter. The pallets are presented with the top deck up for initial inspection, then rotated deck-side down to allow undercarriage checks and debris removal. A turntable enables thorough inspection from all angles.
Pallets suitable for direct reuse are automatically routed to one of eight post-repair stackers. Units that don’t fit designated categories are automatically discharged for separate handling. Damaged pallets are conveyed to the upper conveyor line, where up to six operators conduct repairs before returning the units to the lower conveyor for reintegration.
“The PSS lines have made a massive difference in terms of throughput, ergonomics and reducing forklift traffic,” Simon stated.
Repair workstations are ergonomically optimized, featuring foot-operated rotating tables and waste conveyors that carry away scrap material for disposal. During system downtime, operators can manually assign destinations using lift-equipped roller conveyors.
The stackers accommodate the most common pallet sizes, including 800×1200 mm and 1000×1200 mm formats. GMA-style 40×48 and 1200×1200 pallets can also be processed without hardware changes.
Each line is equipped with a SCADA (Supervisory Control and Data Acquisition) system that controls operations and generates daily spreadsheet output with detailed productivity and performance data. A mobile app provides supervisors with live updates on throughput and individual operator performance.
Manufacturing and Capacity
From its Doncaster flagship facility, J4P features production capacity for more than 80,000 new pallets weekly. Its nailing lines include a Viking Turbo, a Viking Champion, a small Storti line, and a Cape line for block pallet production.
“We’ve continued to reinvest in new equipment,” explained Simon. “We’re not just refurbishing pallets anymore. New manufacturing has become a major part of our offering.” The Doncaster facility includes 40,000 square feet of manufacturing and 100,000 square feet of storage space.
Logistics, Collection, and Sorting
J4P operates a private fleet of over 100 trailers and 20 lorries or tractors, supplemented by regional transport partners. “That gives us more control over delivery outcomes and quality of service,” Simon said.
While most pallet sorting and repair occurs at the hubs, customer-specific sortation may happen on-site. “Purchase and collection are key parts of our used pallet side of the business,” Simon noted. “We drop trailers at customer locations, and we collect returns and surplus pallets. That’s part of how we balance supply and demand.”
J4P also provides asset tracking and reusable packaging washing services. Cleaning services are offered exclusively for plastic items. “It’s an automated line,” he said. “Two hot washes—45 and 55 degrees Celsius—plus pH-neutral detergents, rinse, air knives, spin dryers, and final inspection. The water is drinking-grade and gets filtered and reused.”
Sustainability in Practice, Looking Ahead
J4P takes its environmental responsibilities seriously. The company is certified by FSC, EcoVadis and Avetta. It has installed solar panels at the Doncaster site to help power operations.
“We’ve made a huge investment in sustainability,” said Craig Bushby, environmental guidance and development lead. Bushby joined J4P earlier this year after previously serving as hazardous waste coordinator for Amazon. “We’re reducing emissions and making our operations more efficient.”
J4P has also been upgrading its forklift fleet. The company recently added two Linde Evo H20 forklifts, known for their hydrostatic drive and fuel efficiency. “They’re smarter,” Bushby noted. “We can track usage via the Linde Connect app. It’s no longer guesswork—we make decisions based on data.”
“And the enhanced LED lighting means we can safely operate outside daylight hours,” he added, which supports J4’s 24-hour, multi-site operations. The machines came fitted with Knapp multi-pallet forklift tynes to improve operator efficiency and boost throughput.”
“We’re really optimistic,” concluded Simon. “We’re continuing to invest in equipment, in people, and in smarter systems. It’s about expanding the width of our network and the depth of our services.”
Michael echoed that sentiment, reflecting on their 30-year journey from farm driveway to international network managed by J4P today: “We’ve come a long way, but there’s still a lot ahead of us,” he said. “We’re proud of what we’ve built, and we’re excited about where we’re going.”
For more information, visit www.junction4pallets.co.uk.
