Have you heard the term Gaylord box and thought, “What in the world is that”? Don’t worry! You’re not alone. The term Gaylord box is commonly used in the shipping industry and has evolved over the years from being just one type of box to being a term that encompasses a range of box products.
Simply put, a Gaylord box is basically a bulk-size corrugated box. Traditionally, Gaylord boxes are large or bulk size and allow for the shipment of products in a large, single container or on a pallet.
The name “Gaylord box” has evolved into a generic term for any pallet-sized box for bulk shipping of storage. The term Gaylord is a trade name for this type of box since the first bulk bins that were manufactured in North American were by the Gaylord Container Company; thus, the name. Similarly to how we say “Kleenex®” for a tissue and “Band-Aid®” for an adhesive bandage, the name stuck, and corrugated boxes were known as Gaylord boxes.
Today, the Gaylord box is synonymous with large corrugated boxes. You may also hear these containers referred to as pallet containers, bulk boxes, pallet boxes, bulk bins, skid boxes, and tote boxes.
Gaylord boxes offer a number of benefits to manufacturers, retailers, and consumers. For one, they are strong, heavy boxes that can handle just about anything placed within them. However, Gaylord boxes are not meant to be used and reused over and over again. They are designed for single-use. The good news is they are completely recyclable. The corrugated material not only makes the boxes inexpensive to manufacture and to use, they also present an eco-friendly solution.
Gaylord boxes are mainly used for shipping, storage, and moving, though they are also used for display purposes. Just one trip around your local grocery store, and you’ll likely see fresh produce or bagged products displayed in Gaylord boxes.
What makes Gaylord boxes perfect for a variety of uses is due to how they are made. Gaylord boxes are made of corrugated cardboard. Corrugated cardboard is a stiff, strong, and lightweight material made up of three layers of brown Kraft paper. This type of paper resists tearing, splitting, and bursting. During the production process, the Kraft paper is crimped and glued to form corrugated cardboard, which is then cut and folded to make boxes. The result is a box that is durable, impact and tear resistant, and flexible. An extra benefit: The use of corrugated cardboard makes them inexpensive and easy to replace.
As the term Gaylord box has evolved into a generic term for any pallet-sized box, there are several different types of boxes sold in a variety of sizes. Gaylord boxes are available in single, double, or triple-wall construction made with corrugated paper.
They all fit onto a pallet, making them perfect to use for shipping and storage. The two main sizes are D Containers and E Containers.
D Container bulk cargo boxes are heavy-duty Double Wall fiberboard containers with a lid. The internal dimensions measure 58”x42”45” and have an approximate weight capacity of 1,200 lbs. In order to reduce shipping costs, the boxes are shipped flat and come disassembled in four parts. They are extremely easy to assemble and do not require glue or staples. Just simply connect the four parts, and they’re ready to use.
The D Container boxes are also available with a pallet, making them even easier to use and ship. The heat-treated stamped pallet has dimensions of 60” x 44” x 95” and an estimated weight of 765 pounds. Each pallet can hold a maximum of 15 Gaylord boxes.
An E Container bulk cargo box is a large corrugated box, with internal dimensions of 41.25” x 28.25” x 24.25”. They are constructed of Heavy-Duty 275# bursting strength Double Wall fiberboard/cardboard.
A Gaylord box is a great item to use for shipping, storage, and moving. Made to be durable and economical, they are extremely versatile and provide a perfect solution for shipping and storage tasks.
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If you need a container for moving or storing large quantities of cargo, you should consider a gaylord box. The most common type of gaylord shipping boxes are pallet containers. These feature walls with anywhere from two to as many as six layers of corrugated cardboard. As with all cardboard boxes, the thickness and paper weights which comprise the walls determines the burst or stacking strength for each box. These ratings tell us how much can be safely placed inside a bulk bin or how many corrugated pallet boxes are safe to stack during shipping or storage.
This specific style of box derives its name from the Gaylord Container Corporation, which was based in St. Louis, Missouri, during the first half of the 20th century. This company filed patents for several unique designs. Even though its packaging design innovations left a lasting impression, gaylord boxes are the only containers that still carry the name of this defunct brand.
Businesses and farmers came to rely on gaylord boxes for transporting products and fresh produce. This style, which fits on a pallet and usually includes a lid, is still used for these purposes today. The cartons are also referred to by generic terms, including bulk boxes or bulk bins, as well as pallet, skid or tote boxes.
Gaylord bins don’t have specific specifications. They can be made from single-wall cardboard clear up to six-wall cardboard. The most common types of bulk bins are built from double-wall and triple-wall corrugated boards and are roughly the size of a standard pallet (though exceptions can be made).
The weight capacity and of corrugated pallet boxes can range from 1,000 to 5,000 pounds depending on the thickness of the walls. It is difficult to safely transport or stack boxes that do not have sufficiently thick walls. All of these factors – from the type of material, size and shape, thickness of walls and the number – can significantly impact the cost of a shipping strategy.
Most gaylord bins meet general standards that make it possible to maneuver these bulk containers with manual or mechanical stocking equipment. You should still ensure that each box is not over packed or so heavy that it exceeds the safe weight rating.
Gaylord containers are ideal for commercial use. Produce and packaged foods are often stored inside of these cartons. Depending on the composition and design of the container, you can fill one with granular substances, powders and even liquid contents. They are also often used for bulk displays in grocery or department stores.
The bulk containers are perfect for containing large amounts of manufacturing materials such as plastic pellets for molding. These bulk boxes can also be an ideal solution for transporting or storing large quantities of electrical or mechanical components. Some types are manufactured to rigorous specifications to allow for the transportation of hazardous waste materials or recycled electronics.
To order the proper gaylord box for your needs, we need to know what you are shipping. Plastic pellets behave more like a fluid in shipping whereas watermelons are more static. We need to calculate how much cargo you want to be able to fit into each gaylord container in both weights and volumes. These measurements and calculations will determine the required cardboard grade and if the units will be stackable.
Finally, we need to determine which style best suits your needs. You can order a gaylord box with a wide range of internal dimensions, and they come in both a rectangular or octagonal shape and with a complete or partial bottom. These factors will impact the number of bulk bins that you’ll need in any given year.
Our experienced packing experts can help you make sure that the specifications of the boxes you choose will stand up to the demands of your cargo. These experts can also offer guidance on the best shipping solutions or strategies. Welch Packaging is a full-service corrugated converter capable of manufacturing a variety of containers made from corrugated cardboard, fiberboard or plastic. We make it easy to obtain any type of container, including a gaylord box, designed to meet your needs.