Compression molded double wall blocks for a pallet and associated methods

A compression molding system comprising:

• a first extruder configured to output melted plastic;
• a second extruder downstream from the first extruder and oriented to mix the melted plastic with wood chips to output a composite material;
• a splitter downstream from the second extruder and oriented to split a flow of the composite material between a first flow and a second flow;
• an inner block transfer valve downstream from the splitter and oriented to receive the first flow of the composite material;
• an outer block transfer valve downstream from the splitter and oriented to receive the second flow of the composite material;
• an inner block accumulator downstream from the inner block transfer valve;
• an outer block accumulator downstream from the outer block transfer valve, wherein the inner block transfer valve and the outer block transfer valve are configured to alternately direct the composite material between the inner block accumulator and the outer block accumulator;
• at least one inner block assembly comprising:
• at least one inner block mold to receive the composite material from the inner block accumulator, and
• at least one inner block press oriented to press the composite material in the at least one inner block mold into a desired shape of at least one inner block having an opening on one side;
• at least one outer block assembly comprising:
• at least one outer block mold to receive the composite material from the outer block accumulator, and
• at least one outer block press oriented to press the composite material in the at least one outer block mold into a desired shape of at least one outer block having an opening on one side;
• and
• a press assembly downstream from the at least one inner and outer block assemblies, and configured to press one of the at least one inner blocks into the opening in one of the at least one outer blocks to form a double wall block.