Gaylord Boxes
Heavy-duty bulk containers built for serious loads. Used gaylords deliver the same performance as new — at up to 60% less cost.
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What is a Gaylord Box?
A gaylord box (also called a bulk bin, pallet box, or tote) is a large corrugated container designed to sit on a pallet. They're the workhorses of the shipping and warehousing industry — used to move everything from auto parts to food products to recycling materials.
The standard gaylord measures 48" x 40" x 36" and can hold up to 2,500 lbs depending on the wall thickness. They come in double-wall and triple-wall configurations, with various flap options for different use cases.
Why buy used? Most gaylords are used only once or twice before being discarded. Our used gaylords are inspected, sorted by grade, and priced at a fraction of new cost. You get the same strength and reliability while keeping materials out of landfills.
Quick Facts
- Most common pallet-sized box in logistics
- Holds 2,500 – 5,000 lbs depending on wall type
- Used gaylords cost 40–60% less than new
- Available in Grade A, B, and C conditions
- We buy and sell in any quantity
The Origin of the Gaylord Box
The term "gaylord box" traces its origins to the Gaylord Container Corporation, founded in St. Louis, Missouri. During the 1950s and 1960s, as American manufacturing and logistics experienced rapid growth, there was a pressing need for a standardized large-format corrugated container that could sit directly on a pallet and be moved efficiently by forklift.
The Gaylord Container Corporation became one of the leading producers of these heavy-duty bulk boxes, and the company name became synonymous with the product itself — much like "Kleenex" for tissues or "Xerox" for photocopies. By the late 1960s, logistics professionals across North America were requesting "gaylords" regardless of which company actually manufactured them.
The Gaylord Container Corporation went through several mergers and acquisitions over the decades, eventually becoming part of Temple-Inland and later International Paper. But the name stuck. Today, "gaylord box" is the universally recognized industry term for any pallet-sized bulk corrugated container, regardless of manufacturer.
The design has remained remarkably consistent since its introduction. The standard 48" x 40" footprint was chosen to match the Grocery Manufacturers Association (GMA) pallet standard, which remains the dominant pallet size in North America. This standardization is a key reason gaylord boxes have remained so popular — they integrate seamlessly into existing warehouse infrastructure, truck dimensions, and racking systems.
Available Sizes
Common gaylord box dimensions we carry in stock
| Dimensions (LxWxH) | Wall Type | Max Weight | Stacking | Common Use |
|---|---|---|---|---|
| 48" x 40" x 36" | Double Wall | Up to 2,500 lbs | 2 high loaded | Standard bulk shipping |
| 48" x 40" x 48" | Double Wall | Up to 2,500 lbs | 2 high loaded | Tall items, lightweight bulk |
| 48" x 40" x 36" | Triple Wall | Up to 4,000 lbs | 3 high loaded | Heavy materials, parts |
| 48" x 40" x 30" | Double Wall | Up to 2,200 lbs | 3 high loaded | Low-profile bulk storage |
| 48" x 48" x 40" | Double Wall | Up to 2,800 lbs | 2 high loaded | Square-format, drums |
| 44" x 36" x 36" | Double Wall | Up to 2,000 lbs | 3 high loaded | Compact bulk, retail |
| 48" x 45" x 36" | Double Wall | Up to 2,500 lbs | 2 high loaded | Wide-format shipping |
| 40" x 30" x 30" | Double Wall | Up to 1,500 lbs | 3 high loaded | Half-size bulk, retail |
| 60" x 48" x 48" | Triple Wall | Up to 5,000 lbs | 1 high loaded | Oversized industrial |
| 58" x 42" x 45" | Triple Wall | Up to 5,000 lbs | 1 high loaded | Oversized, industrial |
| 48" x 40" x 24" | Double Wall | Up to 2,000 lbs | 4 high loaded | Short bulk, heavy parts |
Don't see the size you need? Contact us — we can source custom dimensions.
Weight Capacity & Stacking Guide
Understanding load limits and stacking guidelines helps you get the most out of your gaylord boxes safely.
| Wall Type | Max Contents Weight | Burst Strength (PSI) | ECT Rating (lbs/in) | Safe Stacking (loaded) | Safe Stacking (empty) |
|---|---|---|---|---|---|
| Single Wall | Up to 1,000 lbs | 200 PSI | 32 ECT | Not recommended | 4 – 5 high |
| Double Wall | Up to 2,500 lbs | 275 PSI | 48 ECT | 2 – 3 high | 6 – 8 high |
| Triple Wall | Up to 5,000 lbs | 700 PSI | 82 ECT | 2 – 3 high | 8 – 10 high |
Note: Stacking limits assume level, dry warehouse floor and evenly distributed loads. Reduce stacking height for used boxes (especially Grade C) and when storing in humid environments.
Flap Configurations
Choose the right flap style for your application
Full Bottom Flaps
All four flaps meet in the center for maximum base support. Standard for heavy loads.
Half Bottom Flaps
Partial flaps that overlap. Often paired with a pallet for additional support.
Full Top Flaps
Complete top closure for fully enclosed shipping. Ideal for loose materials.
No Top Flaps
Open-top design for easy access. Common in warehouse storage applications.
Common Uses by Industry
Gaylord boxes serve virtually every industry. Here's how different sectors put them to work.
Automotive
Gaylords are used extensively in auto manufacturing for collecting and transporting scrap metal, plastic trimmings, and work-in-process parts between assembly stations. Suppliers ship components like bumpers, dashboards, and wiring harnesses in triple-wall gaylords.
Food & Beverage
Used for bulk storage of dry goods, produce collection at farms, and consolidating packaged products. Food-grade liners can be added for direct food contact. Wax-coated options available for moisture resistance.
Recycling & Waste
The most common use for gaylord boxes. Recycling facilities use them to sort and store plastics, paper, textiles, and e-waste. Their large capacity makes them ideal for high-volume material collection.
Retail & E-Commerce
Distribution centers use gaylords for receiving bulk inventory from manufacturers, consolidating returns, and sorting outbound orders. Their pallet-sized footprint integrates with warehouse racking systems.
Agriculture
Farms and packing houses use gaylords for harvesting fruits, vegetables, nuts, and grains. Ventilated options allow airflow for produce. They are also used to collect and transport animal feed ingredients.
Manufacturing
Assembly plants use gaylords for inter-facility transfers of raw materials, component parts, and finished goods. They serve as mobile storage bins on the production floor and in staging areas.
Chemicals & Plastics
Gaylords hold plastic pellets (resin), powders, granular chemicals, and finished plastic products. Liner bags can be used to prevent contamination and make cleanup easier.
Pharmaceuticals
Used for collecting and transporting pharmaceutical waste, returned medications, and bulk packaging materials. Clean, Grade A gaylords are preferred for pharmaceutical applications.
How to Choose the Right Gaylord
Selecting the right gaylord box depends on several factors. Use this guide to match your application with the best container.
1. Determine Your Load Weight
Weigh your contents or estimate total fill weight. Loads under 2,500 lbs work with double-wall. For heavier loads up to 5,000 lbs, choose triple-wall. Always leave a safety margin of at least 10%.
2. Consider Your Contents
Sharp or abrasive items need thicker walls. Liquids or moisture-producing contents need liner bags. Loose granular materials benefit from full-flap enclosure. Match the box features to what goes inside.
3. Choose Your Flap Style
Full bottom flaps provide maximum base support for heavy loads. Half flaps are more economical and work well on pallets. Full top flaps enclose contents completely. Open-top designs allow easy loading and unloading.
4. Select the Right Grade
Grade A for customer-facing or food-related applications. Grade B for B2B shipping and warehousing where appearance matters less. Grade C for recycling collection, internal storage, and budget-conscious applications.
5. Plan for Stacking
If you need to stack loaded gaylords, wall thickness matters significantly. Double-wall supports 2-3 high stacking. Triple-wall supports 2-3 high even with heavy loads. Always use a pallet between stacked layers.
6. Factor in Reuse Needs
If you plan to reuse boxes multiple times, invest in Grade A or B with heavier wall construction. For single-use applications like recycling collection, Grade C provides the best value.
Care & Handling Tips
Proper handling extends the life of your gaylord boxes and prevents damage to contents.
Stacking Limits
Never exceed the recommended stacking height for your wall type. Always place a pallet or sheet of plywood between stacked layers to distribute weight evenly. Reduce stacking in humid environments.
Moisture Protection
Store gaylords indoors or under cover. Even brief exposure to rain or standing water can compromise structural integrity. Use liner bags for contents that may produce condensation or moisture.
Proper Storage
Store unused gaylords flat or nested to save space. Keep them off the ground on pallets. Avoid storing near heat sources, which can dry out the corrugated material and reduce strength.
Forklift Handling
Always lift gaylords by the pallet, never by the box itself. Ensure forks are fully inserted under the pallet before lifting. Avoid piercing the box walls with forks — this is the most common cause of gaylord damage.
Gaylord Box FAQ
Answers to the most common questions about gaylord boxes.
What is the difference between single-wall, double-wall, and triple-wall gaylords?
Single-wall gaylords have one layer of corrugated fluting and are suitable for lighter loads up to 1,000 lbs. Double-wall has two layers of fluting and handles up to 2,500 lbs — this is the most common type. Triple-wall has three layers and can support loads up to 5,000 lbs, making it ideal for heavy industrial applications.
How many times can a gaylord box be reused?
A well-maintained double-wall gaylord can typically be reused 3 to 8 times depending on the contents, handling, and storage conditions. Triple-wall gaylords tend to last even longer. Proper stacking, moisture avoidance, and careful forklift handling all extend the usable life of a gaylord.
Can gaylord boxes be used for food products?
Yes, with appropriate precautions. For direct food contact, a food-grade polyethylene liner bag should be used inside the gaylord. Wax-coated gaylords provide additional moisture resistance. We recommend Grade A gaylords for food applications to ensure cleanliness.
What does the grade mean for used gaylords?
Grade A gaylords are like new with minimal wear — ideal for customer-facing or food-related applications. Grade B gaylords show light wear but are structurally sound — great for B2B shipping. Grade C gaylords have visible wear and may have labels or writing, but they are fully functional for storage and recycling use.
Do you sell gaylord boxes with pallets included?
Yes, we offer gaylords with or without pallets. Many customers prefer to purchase them as a set for easier handling and shipping. We carry standard 48x40 GMA pallets that pair with our most popular gaylord sizes. Bundle pricing is available.
What is the minimum order quantity for gaylord boxes?
There is no strict minimum. We sell gaylords in quantities as small as 1, though per-unit pricing improves significantly at 25, 50, 100, and truckload quantities. Contact us for volume pricing based on your specific needs.
Need Gaylord Boxes?
Whether you need 10 or 10,000 — we have the inventory and the logistics to deliver.
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