What Are Gaylord Boxes and How Are They Used in Shipping?

When standard shipping containers reach their limit, the Gaylord box steps in as the ultimate solution for bulk transport and storage. The word Gaylord does sound like a brand name. But to logistics professionals it is a perfect intersection of massive capacity and cost-effective durability. Also known as pallet containers and bulk bins, Gaylord packaging boxes can hold thousands of pounds of material.

Read this blog to understand the specs and applications of these corrugated powerhouses. Because if you deal in bulk shipping you might need them one day. 

What exactly is a Gaylord box?

Before we dive into its uses and application, let’s find out what is a Gaylord container’s history and the mystery behind its name. 

The term ‘Gaylord’ is actually an eponymous trademark. It originated from the Gaylord Container Company, the firm that pioneered the design and manufacturing of corrugated cardboard shipping boxes. Although the firm was later dissolved through mergers, the name survived. Today, ‘Gaylord’ is used generically to describe any pallet-sized bulk box, much like people use ‘Kleenex’ to refer to tissues. 

The anatomy of Gaylord packaging boxes

A Gaylord box isn’t just any ordinary moving carton, it is engineered for industrial-grade durability. These high-strength cartons feature layered fluting for maximum crush resistance and impact absorption. A standard Gaylord box dimensions are 48″ x 40″ with heights typically ranging from 24″ to 48″. Apart from the standard you can customize Gaylord cardboard boxes in the following sizes:

• 40″ x 40″ x 40″
• 36″ x 36″ x 36″
• 45″ x 45″ x 40″
• 48″ x 40″ x 48″

The most common shapes of these boxes include rectangular (four-sided) and octagonal (octabin) for superior stacking strength. However, some versions are integrated with “bottom flap” or a separate corrugated tray. The purpose of these additional features is to prevent the product from leaking out the bottom. Most Gaylord boxes are constructed with double and triple-wall but you can go up to six-wall thickness for high durability. Many Gaylords also come with corrugated id. This protects items from dust and debris, while allowing for stacked, high-density storage.

How are Gaylord packaging boxes used in shipping?

Many companies still don’t know what are Gaylords in shipping and how much they matter. Well, for businesses looking to slash handling times and maximize trailer space, the Gaylord boxes are the ultimate logistical shortcut. They are the “Swiss Army Knife” of the shipping world. While they are found in almost every industry, they are most vital in the following four sectors:

Bulk Solids & Raw Material: Starting with the flowable bulk solids. This includes plastic pallets, chemical resins, and industrial powder. Instead of going through the hassle of shipping hundreds of small 50lb bags, companies can ship 2000+lbs material in a single Gaylord container. 

Agriculture & Produce: Gaylord containers make good “Bin Boxes”. Grocery stores use them to hold large watermelons, pumpkins, or bags of potatoes. Whereas farmers use them to move produce from the field to the retail floor. 

Waste management and recycling: For those who don’t know Gaylords are the gold standard for scrap collection. From paper shredding, e-waste to scrap metal, these boxes provide a low-cost way to accumulate heavy waste.

The benefits of using Gaylord boxes

Beyond their physical strength, the true value of these boxes lies in their circularity. Easy to source, easy to reuse, and easy to recycle. These are a few benefits of using Gaylord packaging, some others are:

Superior space efficiency

In a warehouse every square foot has a price tag which means floor space is expensive and comes with a fixed overhead. But the air above the floor space is free. Since Gaylord boxes are rigid and stackable, you can utilize the vertical height of the warehouse. You can turn one pallet of floor space into three or four levels of storage without crushing or breaking the content. 

Unmatched cost-effectiveness

Minimizing shipping expenses is the top priority of every business. By using Gaylord packaging boxes you can save big. Since they are made from cardboard, these boxes are lighter than metal. Thus, you can reduce the overall “tare weight” of your shipments and avail lower shipping rates. 

Enhanced safety and load stability

Shipping flowable items and heavy powders is a safety risk. There is a 20 to 30% chance of combustible dust explosions, hazardous cargo shifts, and environmental contamination from leaks. The thick multi-wall Gaylord acts as a fortress for these items by preventing punctures and blowouts during transit. 

Apart from these advantages, Gaylord packaging boxes are a standout performer in the green-conscious economy. At the end of their life, you can easily recycle them. Thus, businesses can significantly reduce their carbon footprint and enhance their reputation as an environmentally responsible organization.

Considerations for choosing the right Gaylord box?

Selecting a Gaylord box isn’t just about finding the biggest container available. It’s about matching the box’s specifications to your specific payload. Choosing the wrong “spec” can lead to collapsed walls, damaged goods, or even safety hazards in your warehouse. Therefore, before ordering Gaylord boxes discuss the following point with your custom packaging supplier. 

Size and Volume: A Gaylord box is only as useful as its ability to be moved. Therefore, picking a box matches the pallets exactly. Small containers demand extra processing; large containers lead to instability.

Weight: Not all cardboard is created equal. So, while evaluating a box, look into metrics. If the content weighs 500-1,000lbs use a single-wall box and if the content weighs between 1,000-4,000lbs then go for triple-wall boxes. 

Liners: Gaylord packaging boxes are made of porous corrugated cardboard. Therefore, if you are shipping flour, pigments, or chemicals use plastic liner as an add-on. It will prevent the moisture from reaching your product. 

Conclusion

Maximizing your shipping budget doesn’t always require high-tech software or complex automation. Sometimes, it just requires the right box. From their collapsible design that saves precious floor space to their incredible burst strength, Gaylord packaging boxes remain the gold standard for bulk transport for a reason. So, if you need brand-new triple-wall boxes for heavy manufacturing or affordable used options for recycling, we can help you find the perfect fit. Contact our team today for a custom quote or to learn more about which Gaylord box is right for your application.

Frequently Asked Questions

What are other names for Gaylord boxes?

Gaylord boxes come with many different names. Some of them are: bulk boxes, pallet boxes, skid boxes, bulk bins and octabins.

How much weight can a Gaylord box hold?

A single-walled box can hold up to 1,000lbs content. Whereas the triple-wall box can handle up to 3,000lbs or more.

Can Gaylord boxes be stacked?

Yes, Gaylord boxes are specifically designed for shipping and warehousing stacking. You can stack up to 3 to 4 levels and save storage space.

Are Gaylord boxes reusable or eco-friendly?

These boxes are made from corrugated cardboard that is an eco-friendly material. Many of these boxes are designed to be reused multiple times before being recycled.

Why should I buy used Gaylord boxes?

Using used boxes is a cost-effective solution and a sustainable option for shipping inexpensive materials.