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Complete Gaylord Box Guide

Everything you need to know about bulk containers

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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.