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What Is a Gaylord Box?

Gaylord boxes are large, corrugated cardboard containers used to store and transport bulk materials. Frequently used in industries such as agriculture, food production, and plastics manufacturing, these boxes are designed to fit one to a pallet, allowing for the easy shipment and delivery of bulk materials.

While Gaylord is the standard packaging industry term, these containers can also be referred to as corrugated bulk bins, skid or pallet boxes, pallet containers, or octabins. The Gaylord Container Company popularized the use of these large boxes in the 1980s, resulting in the name that we know them by today.

Common Gaylord Box Shapes

Gaylord boxes come in two shapes: rectangular and octagonal.

Rectangular boxes are easy to handle and maintain their shape well, making them ideal for machinery use.

Octagonal boxes have reinforced corners for better weight distribution and are suited for irregular-shaped items like pumpkins or mixed merchandise.

Illustration of a Rectangular Gaylord Box
Rectangular
Illustration of an octagonal Gaylord box
Octagonal

Types of Gaylord Boxes

Gaylord boxes come in a variety of styles that cater to various storage and transport needs. While standard Gaylord boxes are commonly used for general bulk storage and shipping, specialized varieties may feature additional reinforcements, liners, or coatings to accommodate items like hazardous materials, food products, or high-weight loads.

Illustration of a produce Gaylord box
Produce

Vented for air circulation, these are used to transport fresh fruits and vegetables.

Illustration of a Gaylord box laminated with resin
Resin

Coated for durability and ideal for transporting damp products.

Illustration of combo Gaylord box
Combo

Reinforced octagonal bins providing secure pallet transport.

Illustration of an HPT Gaylord Box
HPT

Sturdy octagonal boxes with high compression strength for heavy loads.

Illustration of HAZMAT Gaylord box
HAZMAT

Built for hazardous materials, these meet safety regulations for secure handling.

Illustration of a Rectangular Gaylord Box
Standard

A rectangular Gaylord box without unique features or custom construction.

What Is Fluting?

Fluting refers to corrugated paper sheets sandwiched between cardboard liners, and a box's wall size, or ply, refers to how many layers of fluting it has.

While other factors can impact the strength of a Gaylord, wall size is a strong indicator of a box's weight capacity and resistance to compression. Most Gaylord boxes have a wall size of 2, 3, 4, or 5.

Boxes with less ply are typically lower in cost, but those with more ply are more likely to be reusable.

Photo of 3-wall box fluting
Illustration of 2-wall box fluting
2-Wall
Illustration of 3-wall box fluting
3-Wall
Illustration of 4-wall box fluting
4-Wall
Illustration of 5-wall box fluting
5-Wall

Wall Size Options

Consider the following when determining which Gaylord boxes are best for your needs:

2-Wall: Features two layers of corrugated board, offering moderate strength for lightweight or less fragile goods.

3-Wall: Built with three layers, providing enhanced durability and better protection for medium-weight loads.

4-Wall: Consists of four layers of corrugated material, suitable for heavier products requiring increased support and stability.

5-Wall: The strongest option, with five layers of corrugated board, ideal for heavy or high-risk shipments requiring maximum protection.

Bottom Styles

The bottom of a Gaylord box impacts its stability, strength, and ease of use, with different styles offering varying levels of support:

Full: Full flaps fold over one another and cover the entire bottom of a Gaylord.

Partial: Partial flaps also fold over one another but cover only part of the bottom.

Insert: A cardboard insert can be used to cover the gap left by partial flaps.

Domelock: Domelock bottoms have interlocking flaps that help stabilize the box.


Illustration of a Gaylord Box With a Full Flap Bottom
Full
Illustration of a Gaylord Box With a Partial Flap Bottom
Partial
Illustration of a Gaylord Box With a Bottom Insert
Insert
Illustration of a Gaylord Box With a Domelock Bottom
Domelock
Illustration of a 48x40x36" octagonal Gaylord box
Illustration of a 48x40x40" octagonal Gaylord box

Size & Dimensions

Gaylord boxes come in a wide range of sizes, and some of the most common dimensions are designed to fit standard 48” x 40” pallets. Heights typically range from 24 to 48 inches, though some boxes can be as tall as 60 inches for high-volume needs.

Common Dimensions

48" x 40" x 36"48" x 40" x 30"48" x 40" x 45"48" x 40" x 24"
48" x 40" x 48"48" x 40" x 18"48" x 45" x 36"48" x 45" x 42"
48" x 38" x 36"45" x 45" x 40"41" x 41" x 38"48" x 48" x 36"
42" x 42" x 40"48" x 42" x 40"47" x 39" x 36"40" x 36" x 36"
46" x 46" x 42"48" x 44" x 34"50" x 48" x 40"48" x 40" x 60"
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