Gaylord Boxes
Heavy-duty corrugated bulk bins for storage, shipping, and material handling. New and quality-graded used options at competitive prices.
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What Are Gaylord Boxes?
Gaylord boxes are large, heavy-duty corrugated containers designed to hold bulk quantities of materials on a standard pallet. Measuring roughly four feet on each side and standing two to four feet tall, they are the workhorses of industrial packaging. Warehouses, factories, farms, and recycling facilities across North America rely on gaylord boxes every day to move, store, and ship everything from auto parts to agricultural produce.
The name "Gaylord" traces back to the Gaylord Container Corporation, a St. Louis-based corrugated packaging manufacturer that pioneered these bulk bins in the mid-twentieth century. Although the company was eventually acquired and absorbed into other firms, the brand name became so widely associated with this style of container that it is now used generically across the industry. You may also encounter the terms pallet box, bulk bin, tote bin, or octabin, all of which refer to similar large corrugated containers.
Construction starts with layers of corrugated fiberboard — a fluted medium sandwiched between flat liner sheets. Single-wall boxes use one fluted layer, double-wall uses two, and triple-wall uses three. Each additional layer dramatically increases strength, puncture resistance, and stacking capacity. The board is die-cut, scored, and folded into a box form with bottom flaps that are glued, stitched, or taped together. Lids, when included, are typically separate pieces that telescope over the top.
At PackMesa, we stock a full range of gaylord boxes — from brand-new triple-wall units rated for 4,500+ pounds to economical used Grade C boxes perfect for recycling collection. Buying used gaylord boxes saves your business up to 70% compared to new, reduces waste headed to landfills, and supports a circular economy for corrugated packaging. Whether you need one box or a full truckload, we deliver throughout Mesa, Phoenix, and greater Arizona.
Technical Specifications
Quality Grading System
Every used gaylord box at PackMesa is hand-inspected and assigned a grade based on structural integrity, cosmetic condition, and remaining usable life. Here is what each grade means.
- Never used — factory fresh condition
- Full structural integrity with zero wear
- Clean, unmarked surfaces on all panels
- All flaps, folds, and scores are crisp
- Manufacturer edge crush and burst ratings fully intact
- Suitable for food-contact and clean-room environments
- Used only once or twice with careful handling
- No punctures, tears, or structural damage
- Minimal cosmetic wear — may have slight scuff marks
- All flaps intact with strong fold memory
- Retains 90%+ of original burst and crush strength
- Suitable for shipping, storage, and most industrial use
- Used multiple times — moderate cosmetic wear
- May have light staining, tape residue, or label marks
- No major punctures — minor repairs may be present
- Structurally sound for most non-critical applications
- Retains 70-90% of original strength ratings
- Great value for warehouse storage and internal transfers
- Heavy use with visible wear and cosmetic imperfections
- May have patched punctures or taped reinforcements
- Possible minor moisture exposure (no active dampness)
- Suitable for non-critical storage and one-time shipping
- Retains 50-70% of original strength
- Lowest cost option — ideal for recycling collection bins
Standard Size Comparison
Gaylord boxes come in a range of standard sizes. Use this table to find the right dimensions for your application.
| Size (L×W×H) | Capacity | Wall Type | Best Use |
|---|---|---|---|
| 48×40×24" | ~26.7 cu ft | Single / Double | Lightweight parts, packaging peanuts |
| 48×40×30" | ~33.3 cu ft | Single / Double | Textiles, plastic components |
| 48×40×36" | ~40 cu ft | Double / Triple | General bulk storage (most popular) |
| 48×40×48" | ~53.3 cu ft | Double / Triple | Lightweight, high-volume materials |
| 48×48×24" | ~32 cu ft | Single / Double | Short bin for heavy items |
| 48×48×36" | ~48 cu ft | Double / Triple | Square footprint — auto parts, castings |
| 48×48×48" | ~64 cu ft | Triple | Maximum volume — foam, insulation |
| 58×42×45" | ~63.6 cu ft | Double / Triple | Oversized / automotive components |
Wall Types Explained
The number of corrugated layers in the box wall is the single biggest factor affecting strength, weight capacity, and price.
Single Wall
One layer of corrugated medium between two liner boards. This is the most economical option and works well for lightweight products, internal transfers, and temporary storage. Single-wall gaylords are easy to fold and store flat when not in use.
Double Wall
Two layers of corrugated medium separated by a liner sheet create significantly greater strength. Double-wall gaylords are the industry standard for most bulk shipping and storage applications. They offer excellent puncture resistance and stacking strength while remaining cost-effective.
Triple Wall
Three layers of corrugated medium provide the maximum structural integrity available in corrugated packaging. Triple-wall gaylords can replace wooden crates for heavy-duty shipping and can withstand significant stacking pressure. They are commonly used for metal parts, machinery components, and export shipments.
How to Choose the Right Gaylord Box
Six key factors to consider before placing your order.
Contents Weight
The total weight of the materials you plan to store or ship is the most critical factor. Single-wall boxes handle up to about 1,500 lbs, double-wall can manage 2,000 to 3,000 lbs, and triple-wall supports 3,500 lbs and above. Always choose a box rated for at least 20% more than your expected load to account for moisture, stacking, and transit stress.
Product Type
Sharp or abrasive contents (metal parts, broken glass) require thicker walls and possibly a liner to prevent puncture. Powders and granular materials need sealed bottom flaps or a poly liner to prevent leakage. Moisture-sensitive goods may need wax-coated or poly-laminated boxes.
Handling & Transit
Boxes that will be forklift-handled, stacked in trailers, or shipped long distances need higher ECT ratings than boxes used only for on-site storage. Consider whether the box will be moved once or many times — frequent handling accelerates wear and reduces effective lifespan.
Storage Environment
Indoor, climate-controlled warehouses are the most forgiving environment. Outdoor exposure, humidity, and temperature swings degrade corrugated board rapidly. If your boxes will be stored outdoors or in a non-climate-controlled facility, invest in heavier wall construction and consider moisture-resistant options.
Stacking Requirements
If you plan to stack loaded gaylord boxes, the ECT (Edge Crush Test) rating matters more than the Mullen burst rating. Each layer of stacking multiplies the compression force on the bottom box. As a general rule, limit stacking to 2-3 high for single-wall, 3-4 for double-wall, and 4-5 for triple-wall boxes.
Budget vs. Lifespan
New boxes offer the longest service life but cost the most. Used Grade A boxes deliver near-new performance at 40-60% savings. Grade B boxes are ideal for one-time use or short-term storage at the lowest cost. Think about how many uses you need — a Grade A box used three times may cost less per use than a new box used five times.
Pricing: New vs. Used
Used gaylord boxes deliver significant cost savings. Actual pricing varies by size, wall type, and order volume — contact us for an exact quote.
| Grade | Typical Price Range | Notes |
|---|---|---|
| New / Unused | $25 - $55 each | Full manufacturer specs. Best for critical or long-term use. |
| Grade A (Like New) | $12 - $28 each | Best value. Near-new performance at 40-60% savings. |
| Grade B (Good) | $6 - $18 each | Great for storage and non-critical shipping. |
| Grade C (Fair) | $3 - $10 each | Lowest cost. Suitable for recycling bins and one-time use. |
Prices are approximate and depend on size, wall type, and order quantity. Volume discounts available on orders of 50+ units.
Common Applications by Industry
Gaylord boxes serve virtually every industry that handles bulk materials.
Manufacturing
- Scrap metal and plastic collection
- WIP (work-in-progress) parts storage
- Finished goods accumulation
- Assembly line feeder bins
Agriculture
- Produce harvesting and sorting
- Grain and feed storage
- Nursery plant transport
- Seed collection and distribution
Retail & Distribution
- Store-to-store bulk transfers
- Return merchandise collection
- Seasonal inventory staging
- E-commerce fulfillment staging
Recycling & Waste
- Mixed recyclable collection
- Paper and cardboard baling feeder
- Electronic waste collection
- Textile recycling bins
Maintenance & Storage Tips
Maximize the lifespan of your gaylord boxes with these best practices.
Environmental Benefits of Buying Used
Waste Reduction
Every used gaylord box that gets a second or third life is one less box sent to a landfill. The U.S. generates over 30 million tons of corrugated waste annually — reuse is the most effective diversion strategy.
Lower Carbon Footprint
Manufacturing a new corrugated box requires harvesting trees, pulping wood, forming board, and shipping finished goods. Reusing an existing box skips the entire manufacturing cycle and its associated CO2 emissions.
Water Conservation
Corrugated board production is water-intensive — an average box requires 10-20 gallons of water to manufacture. Extending the life of existing boxes conserves thousands of gallons per truckload.
Circular Economy
When a used box finally reaches end-of-life, it is still 100% recyclable. The fibers are pulped and reformed into new corrugated products, completing the loop. Buying used maximizes the total value extracted from each raw material input.
Frequently Asked Questions
Why are they called "Gaylord" boxes?
The name comes from the Gaylord Container Corporation, a major corrugated packaging manufacturer based in St. Louis that popularized these large bulk containers in the mid-20th century. Although the company was acquired in 1986, the name stuck as an industry-standard term. You may also hear them called bulk bins, pallet boxes, pallet containers, or tote bins.
What is the weight limit for a gaylord box?
Weight limits vary by wall type and construction. Single-wall gaylords typically support 1,000 to 1,500 lbs. Double-wall versions handle 2,000 to 3,000 lbs. Triple-wall gaylords can support 3,500 to 4,500+ lbs. Always check the box manufacturer stamp for the certified weight rating and reduce capacity by 10-20% for used boxes to account for material fatigue.
Can I stack loaded gaylord boxes on top of each other?
Yes, but with important limitations. The stacking capacity depends on the ECT (Edge Crush Test) rating, not the burst strength. Single-wall boxes should generally not be stacked more than 2 high when loaded. Double-wall boxes can typically support 3-4 high stacking. Triple-wall boxes can handle 4-5 levels. Always ensure the weight on the bottom box does not exceed its rated capacity, and use plywood sheets between layers to distribute the load evenly.
Do I need a liner inside a gaylord box?
Liners are recommended for powders, granules, small parts, and any material that could leak through the seams. Polyethylene (PE) liners are the most common and cost-effective option. For food-contact applications, use FDA-compliant food-grade liners. Anti-static liners are available for electronic components. Liners also help protect the box from contamination, extending its usable life.
What pallet size do gaylord boxes fit on?
Most gaylord boxes are designed for the 48×40-inch GMA (Grocery Manufacturers Association) standard pallet, which is the most widely used pallet size in North America. Larger 48×48-inch gaylords fit square pallets of the same dimension. Always verify that the box footprint matches your pallet size to prevent overhang, which creates instability during forklift handling and transit.
Are used gaylord boxes recyclable?
Absolutely. Corrugated cardboard is one of the most recycled materials in the world, with a recycling rate exceeding 90% in the United States. When a gaylord box reaches the end of its useful life, it can be broken down flat and sent to any cardboard recycling facility. The fibers are pulped and reformed into new corrugated products. Buying used gaylords and then recycling them at end-of-life creates a full circular economy loop.
How many times can a gaylord box be reused?
A new triple-wall gaylord box in ideal conditions can often be reused 5-10 times before it needs to be retired. Double-wall boxes typically last 3-6 uses. Single-wall boxes are often limited to 1-3 uses. Factors that reduce lifespan include moisture exposure, heavy loads at or near the rated capacity, rough handling, outdoor storage, and sharp or abrasive contents. Inspecting each box before reuse is essential.
What is the difference between ECT and Mullen burst strength?
ECT (Edge Crush Test) measures a box's resistance to compression force from top to bottom — critical for stacking strength. It is expressed in pounds per linear inch (e.g., 32 ECT, 48 ECT). Mullen burst strength measures resistance to puncture force applied perpendicular to the box wall — important for rough handling. It is expressed in pounds per square inch (e.g., 200#, 275#). For stacking applications, prioritize ECT. For shipping where boxes may be impacted, prioritize Mullen burst.
What is the minimum order quantity?
At PackMesa, we have no strict minimum order. We sell individual gaylord boxes for small operations and offer volume pricing for orders of 50, 100, 250, and 500+ units. Bulk orders typically ship on full truckloads for maximum freight efficiency. Contact us for a custom quote based on your quantity, size, and grade requirements.
Can you deliver gaylord boxes to my facility?
Yes. We offer delivery throughout the Mesa, Phoenix, and greater Arizona metro area using our own fleet. For orders shipping outside Arizona, we arrange LTL (less-than-truckload) or FTL (full truckload) freight through our carrier network. Delivery timelines and costs vary by distance and volume — request a quote and we will provide a complete landed cost estimate.
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