Complete Gaylord Box Guide
Everything you need to know about bulk containers
What is a Gaylord Box?
A Gaylord box, also known as a bulk bin, pallet box, or tote, is a large corrugated cardboard container typically designed to sit on a standard pallet. The name comes from the Gaylord Container Corporation, which originally manufactured these containers.
Today, "Gaylord" has become a generic term for any large bulk cardboard container, regardless of manufacturer. These boxes are essential for industries requiring efficient bulk storage, shipping, and materials handling.
Quick Facts
- Typical Size: 48" x 40" x 36" (fits standard pallets)
- Weight Capacity: 1,000 - 2,500 lbs depending on construction
- Materials: Single, double, or triple wall corrugated cardboard
- Common Uses: Manufacturing, warehousing, agriculture, recycling
Common Uses
Manufacturing
Parts storage, WIP inventory, shipping
Warehousing
Bulk storage, order picking, staging
Agriculture
Produce, grain, farm supplies
Recycling
Material collection, sorting, transport
Retail
Back stock, returns, seasonal
Shipping
Bulk freight, LTL, international
Types of Gaylord Boxes
By Wall Construction
- Single Wall: Lightweight, economical, best for lighter loads (up to 1,000 lbs)
- Double Wall: Standard industrial use, handles 1,500-2,000 lbs
- Triple Wall: Maximum strength, heavy-duty applications up to 2,500 lbs
By Style
- 4-Wall: Standard rectangular box, most common type
- Octagon: Eight-sided, reduces material trapped in corners
- Full Bottom: Single-piece bottom, no seams
- Half-slotted: Open top design for easy access
New vs. Used: Which to Choose?
Choose New When:
- • Food/pharmaceutical applications
- • Clean room environments
- • Customer-facing displays
- • Maximum load capacity needed
Choose Used When:
- • Budget is a priority
- • Internal storage/shipping
- • Environmental sustainability matters
- • Short-term or single-use needs
Care and Maintenance Tips
- Store in dry conditions - moisture is the enemy of cardboard
- Don't exceed weight limits, even if the box looks sturdy
- Inspect regularly for damage that could affect safety
- Stack carefully and evenly to prevent crushing
- Consider repairs for minor damage instead of replacement
Ready to Order?
Now that you know about Gaylord boxes, let us help you find the right ones for your needs.
Frequently Asked Questions
What makes a box a "Gaylord" box?
It is a large corrugated bulk bin designed for pallet use, typically 48" x 40" with double or triple-wall construction.
Where did the term come from?
The name traces back to the Gaylord Container Company, an early manufacturer of these bulk bins.
What are common uses?
Bulk material storage, loose parts collection, recycling, agricultural produce, and e-commerce returns are common applications.
How are Gaylord boxes constructed?
They use heavy corrugated board, often double or triple-wall, and are designed to sit securely on pallets.
Can they handle liquids?
With liners, certain Gaylord boxes can hold semi-liquids or granular material. Always verify wall strength and use liners.
How do I store Gaylord boxes?
Store nested or flat in a dry area. Avoid moisture and crush risk to preserve wall strength.
Are there standard sizes?
48" x 40" footprints are standard; heights vary from 24" to 60"+. Specialty footprints exist for automotive and other sectors.
How do I move them safely?
Move with forklifts or pallet jacks using pallets sized for the box footprint, and strap loads to prevent shifting.
Can Gaylord boxes be recycled?
Yes. They are fully recyclable. We can pick up damaged boxes and recycle them through certified mills.
How long do they last?
Lifespan depends on handling and grade. Grade A boxes can see many reuse cycles with careful storage.