Complete Guide to Industrial Packaging Types
Everything you need to know about gaylord boxes, IBC totes, pallets, bulk bags, corrugated boxes, and drums — when to use each, their pros and cons, and how to choose the right option.
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Gaylord Boxes
Also known as: Bulk Bins, Octagon Boxes, Tote Boxes
Large corrugated containers designed for bulk storage and shipping. They sit on standard pallets and can hold up to 4,000 lbs depending on wall thickness.
Advantages
- +Cost-effective for bulk materials
- +Lightweight and stackable
- +Available in single, double, and triple wall
- +Recyclable and biodegradable
- +Collapsible for return shipping
Limitations
- –Not waterproof without liners
- –Limited reuse cycles (3-5 trips)
- –Can weaken in humid conditions
- –Not suitable for liquids
Applications
- •Automotive parts storage
- •Agricultural products
- •Recycling collection
- •Manufacturing scrap
- •Retail distribution
IBC Totes
Also known as: Intermediate Bulk Containers, Liquid Totes
Rigid containers with 275-330 gallon capacity, featuring a plastic inner bottle inside a steel cage on a pallet base. Ideal for liquids, powders, and granular materials.
Advantages
- +Reusable for many cycles
- +Forklift accessible
- +Sealed system prevents contamination
- +Bottom discharge valve for easy dispensing
- +Stackable when full
Limitations
- –Higher upfront cost than disposable options
- –Require cleaning between uses
- –Heavy when full (2,500+ lbs)
- –Limited to standard sizes
Applications
- •Chemical storage and transport
- •Food-grade liquids
- •Pharmaceutical ingredients
- •Water and beverage processing
- •Agricultural chemicals
Pallets
Also known as: Skids, Platforms
Flat transport structures that provide a stable base for stacking, storing, and moving goods. Available in wood, plastic, and metal construction.
Advantages
- +Universal compatibility with forklifts
- +Standardized sizes for efficient shipping
- +Wood pallets are inexpensive and repairable
- +Plastic pallets are moisture-resistant and long-lasting
- +Recyclable in all material types
Limitations
- –Wood pallets can harbor pests (ISPM-15)
- –Heavy (40-75 lbs for wood)
- –Plastic pallets cost 3-5x more upfront
- –Can splinter or crack with age
Applications
- •Warehouse storage
- •Truck and container loading
- •Retail distribution
- •International shipping
- •Automated systems
Bulk Bags (FIBC)
Also known as: Super Sacks, Big Bags, Jumbo Bags
Flexible woven polypropylene bags designed to carry 1,000-4,000 lbs of dry, flowable materials. Equipped with lifting loops for crane or forklift handling.
Advantages
- +Extremely cost-effective per unit of volume
- +Lightweight (5-7 lbs empty)
- +Fold flat for easy storage and return
- +Available with various fill and discharge options
- +Suitable for fine powders to large granules
Limitations
- –Single-use in many applications
- –Not suitable for liquids
- –Can be difficult to fully empty
- –UV degradation if stored outdoors
- –Require overhead lifting equipment
Applications
- •Sand, gravel, and aggregates
- •Chemical powders
- •Agricultural grains and seeds
- •Food ingredients (flour, sugar, salt)
- •Construction materials
Corrugated Boxes
Also known as: Cardboard Boxes, RSC, Shipping Boxes
The most versatile and widely used packaging format. Made from fluted corrugated fiberboard in various sizes, wall thicknesses, and strengths for virtually any application.
Advantages
- +Low cost and widely available
- +Lightweight yet strong
- +Highly customizable in size and print
- +Recyclable with high recovery rates
- +Excellent stacking strength when dry
Limitations
- –Lose strength when wet
- –Limited weight capacity vs rigid containers
- –Single-use in most applications
- –Quality varies by manufacturer
Applications
- •E-commerce shipping
- •Retail packaging
- •Moving and relocation
- •Parts and components
- •Food packaging
Drums & Barrels
Also known as: Steel Drums, Plastic Drums, Fiber Drums
Cylindrical containers available in steel, HDPE plastic, and fiber construction. Standard sizes of 30 and 55 gallons, designed for liquids, powders, and hazardous materials.
Advantages
- +Extremely durable and long-lasting
- +UN/DOT rated options for hazmat
- +Excellent for long-term storage
- +Tamper-evident closures available
- +High crush resistance
Limitations
- –Heavy and difficult to handle manually
- –Higher cost per unit of volume
- –Round shape wastes storage space
- –Steel drums can rust without coating
Applications
- •Hazardous material transport
- •Chemical storage
- •Food-grade liquid storage
- •Waste collection
- •Oil and lubricants
Material Comparisons
Side-by-side comparisons to help you choose the right material for your needs.
Wood vs Plastic Pallets
| Factor | Wood | Plastic Pallets |
|---|---|---|
| Upfront Cost | $8-25 per pallet | $30-100 per pallet |
| Lifespan | 3-5 years / 15-20 trips | 10+ years / 100+ trips |
| Weight | 40-75 lbs | 15-50 lbs |
| Moisture Resistance | Low — can warp, mold | High — fully waterproof |
| Repairability | Easy and inexpensive | Difficult / not repairable |
| International Shipping | Requires ISPM-15 heat treatment | No treatment required |
| Best For | Domestic shipping, one-way trips | Closed-loop systems, clean environments |
Single Wall vs Double Wall Corrugated
| Factor | Single Wall | Double Wall Corrugated |
|---|---|---|
| Thickness | 1/8" (3mm) | 1/4" (6mm) |
| Burst Strength | 200 lbs/sq in | 275-350 lbs/sq in |
| Weight Capacity | Up to 65 lbs | Up to 120 lbs |
| Cost | Lower | 30-50% more |
| Stacking Strength | Moderate | High |
| Best For | Lightweight products, retail | Heavy items, industrial shipping |
How to Choose the Right Packaging
Consider these key factors when selecting industrial packaging for your operation.
Product Weight
Match container capacity to your heaviest loads. Always leave a 10-20% safety margin below the rated weight limit.
Material Type
Liquids need sealed containers (IBC totes, drums). Dry goods work in bags, boxes, or open containers.
Trip Frequency
One-way shipping favors low-cost options (corrugated, bulk bags). Closed-loop systems justify reusable containers.
Environmental Conditions
Consider moisture, temperature, UV exposure, and chemical compatibility when choosing materials.
Handling Equipment
Ensure your facility has the right equipment — forklifts for pallets/totes, overhead cranes for bulk bags.
Regulations
Hazmat requires UN-rated containers. International wood pallets need ISPM-15 treatment. Food needs FDA-compliant materials.
Need Help Choosing?
Our packaging experts can recommend the optimal type and configuration for your specific application and budget.