The Gaylord box market stabilized in 2024-2025. After years of ups and downs, supply chains are normalizing. Steady demand is also helping the industry grow moderately. This guide gives important details about Gaylord boxes. It covers their dimensions, weight, construction, design, market trends, and sustainability. It helps businesses make smart choices about these useful bulk containers.

Origins and Terminology

Gaylord boxes are big, strong corrugated containers. They were first made by the Gaylord Container Company in North America. These strong containers are popular in many industries. They are valued for their durability and large capacity. They go by many names in various industries.

These include:

• bulk box
• jumbo box
• pallet box
• skid box
• bulk bin
• bulk cargo container
• heavy-duty box
• tote
• pallet container
• octabin

These terms all mean the same thing: a big, light but strong cardboard box for storing and moving items in bulk.

Market Overview and Growth Projections

The global market for corrugated bulk bins, like Gaylord boxes, was worth USD 11.6 billion in 2020. It is expected to reach USD 15.4 billion by 2025. This growth represents a Compound Annual Growth Rate (CAGR) of 4.2%. The global industrial bulk packaging market was worth USD 26.14 billion in 2023. It is set to grow at a rate of 3.2% each year from 2024 to 2030.

This growth comes from more industrial activity, especially in developing areas. It also results from the rise in global trade and long-distance commerce. Also, the focus on sustainability and eco-friendly packaging has helped the market grow.

Standard Gaylord Box Sizes

Gaylord boxes are available in different standard sizes. They are made to meet various storage and shipping needs. These sizes are designed to fit standard pallets. This improves transportation efficiency and helps with storage.

Most Common Dimensions

The standard size Gaylord box measures 48″ long, 40″ wide, and 36″ tall. This is by far the most common size, typically featuring an octagonal design with three to five walls. You can double stack these standard boxes when they are full. They match the dimensions of standard pallets exactly. About 500 to 550 boxes can fit on one trailer. This depends on how they are palletized.

The 40″ x 40″ x 40″ cube-style box is another popular option. This design has the same size on all sides. It helps to balance weight, which makes stacking and moving easier.

Other common Gaylord box sizes include:

• 48″ x 40″ x 41″ – A slightly taller variation of the standard size
• 48″ x 40″ x 38″ – Another height variation of the standard footprint
• 48″ x 40″ x 30″ – A shorter version for lighter loads
• 40″ x 30″ x 30″ – Medium-sized option with capacity for 1,200–1,500 pounds
• 36″ x 36″ x 36″ – One of the smallest standard Gaylord boxes, typically holding 1,000–1,200 pounds
• 48″ x 48″ x 48″ – Large cubic design for maximum volume storage

The bases of Gaylord boxes typically come in five standard sizes: 36″x36″, 40″x40″, 40″x48″, 48″x40″, or 48″x48″. These dimensions match wooden pallet sizes. This design boosts carrying capacity and makes forklift transport easier.

Specialized Container Sizes

Beyond standard sizes, several specialized Gaylord containers serve specific purposes:

D-container: Features internal dimensions of 58″ x 42″ x 40″ (without pallet) and measures 58″ x 42″ x 45″ with pallet. These containers are made of 350# double wall fiberboard. They can hold about 1,200 pounds.

E-container: This is smaller than D-containers. Its internal dimensions are 41.25″ x 28.25″ x 24.25″. The external dimensions are 42″ x 29″ x 25.5″. They’re constructed with 275# double wall fiberboard.

Cubic Yard Box: These containers are 36″ x 36″ x 36″. They have a six mil inner liner glued inside. The outer layer is made of polypropylene with a three-wall corrugated sleeve. They can handle heavy loads, with a capacity of 3,000 pounds. Also, they are UN-approved for transporting hazardous materials.

Heavy-Duty Octabin: This 48″ x 40″ x 44″ octagonal container has triple-wall construction. It fits standard 48″ x 40″ GMA pallets. Its eight points of contact provide enhanced stability compared to rectangular designs.

2024-2025 Pricing Trends

The Gaylord box market is stabilizing after years of ups and downs. In 2021-2022, the market saw wild changes. This was because of supply chain issues and high demand. Prices soared as businesses scrambled to secure packaging solutions. The subsequent oversupply in 2023 resulted in softer prices. In 2024, things changed. Excess inventory got used up, and demand for Grade A and Grade B boxes went up.

Pricing by Grade (2024)

Gaylord boxes come in three grades. Their prices change throughout the year.

Month	Grade A ($)	Grade B ($)	Grade C ($)
January	15.50	12.30	10.00
February	15.70	12.40	10.10
March	15.80	12.50	10.20
April	16.00	12.60	10.30
May	16.10	12.70	10.40
June	16.20	12.80	10.50
July	16.30	12.90	10.60
August	16.40	13.00	10.70
September	16.50	13.10	10.80
October	16.60	13.20	10.90
November	16.70	13.30	11.00
December	16.80	13.40	11.10

Pricing can also vary significantly by location. For example, in December 2024, a Grade A Gaylord box cost $16.50 in Alabama, $18.00 in Alaska, and $18.50 in California.

Gaylord Box Weight Specifications

The tare weight (empty weight) of Gaylord boxes is key. It helps you figure out the net weight of the contents and plan shipping logistics.

Tare Weight Examples

• A 48″ x 40″ x 36″ double wall Gaylord box typically weighs approximately 15 pounds
• A 48″ x 40″ x 41″ four-wall rectangular Gaylord box weighs approximately 45 pounds
• A 48″ x 40″ x 41″ heavy-duty octagon five-wall Gaylord box weighs approximately 40 pounds
• A 48″ x 48″ x 48″ double-wall Gaylord container weighs approximately 16 pounds

Gaylord boxes with more corrugated walls and thicker fiberboard generally weigh more. The extra weight means stronger and tougher boxes. This helps them hold heavier loads and survive rough handling while being shipped.

The standard Gaylord box measures 48″ x 40″ x 36″ and costs about $17.85 in 2025. Optional lids are available for separate purchase.

Wall Construction and Weight Capacity

The strength and durability of a Gaylord box rely heavily on how its walls are built. Corrugated containers have two main parts. The outer layer is called linerboard. Inside, there is medium, which is the wavy paper. Gaylord boxes come in single-wall to five-wall designs. Each type offers varying strength and protection levels.

Wall Types and Capacity

Single-wall construction: Consists of one medium glued between two sheets of linerboard. Supports between 65–95 pounds depending on the cardboard grade used. The ECT (Edge Crush Test) rating for single-wall boxes usually falls between 23-55 lb/in. Their burst strength ratings range from 125 to 350 pounds.

Double-wall construction: This design offers added strength. It includes three sheets of linerboard and two medium layers in between. These boxes typically support between 95–120 pounds. Double-wall boxes have ECT ratings from 42 to 82 lb/in. Their burst strength ranges from 200 to 600 pounds.

Triple-wall construction: Consists of four sheets of linerboard with three mediums in between. Much stronger than double-wall, typically holding 120-280 pounds. Some heavy-duty triple-wall cardboard can support up to 300 pounds. Triple-wall boxes have ECT ratings from 67 to 112 lb/in. Their burst strength ranges from 700 to 1300 pounds.

Four-wall construction: Industrial-grade containers often featuring reinforced bottoms with wood pallets. These typically have a weight capacity between 2,000–2,500 pounds.

Five-wall construction: This is the strongest setup. It offers great durability and can hold weights from 4,000 to 5,000 pounds. These strong boxes are made for tough jobs. They offer great protection while being transported.

Manufacturing Process

Knowing how Gaylord boxes are made helps us understand their strength and durability.

The Corrugator Process

A corrugator is a machine that combines three, five, or seven sheets of paper. It creates single, double, or triple wall board in a continuous process. The manufacturing involves three key stages:

1. Three sheets of containerboard unroll on the corrugator. They glue together to form a single liner with flutes. These are the inner liner, the outer liner, and the middle medium (fluting). The medium sheet is given a wave-like shape by pressing it under heat through grooved metal rolls.
2. Gluing the outside liner to create a rigid board: Apply starch to the tips of the flutes on one side. Then, glue the outer liner to the tips of the corrugated medium from the outside. Also, glue the inner liner to the tips from the inside.
3. Cutting the board to size: The corrugated board exits the corrugator flat. Then, it’s cut to the desired dimensions.

Converting Process

Converting corrugated board means changing a flat board into a final product. These processes consist of printing, die-cutting, folding, and gluing (taping or stitching). We do different tasks depending on what the customer wants and the packaging type needed.

Corrugated Flutes and Strength Testing

Flute Types

Corrugated flutes are key to making Gaylord boxes. There are five main types:

• A Flute: This is the thickest choice at about 5mm (¼ inch). It gives great protection for fragile or heavy items.
• B Flute: Medium thickness at about 3.2mm (⅛ inch), ideal for inner packaging and printing
• C Flute: This is the second-thickest choice, about 3.2mm (11/64 inch). It’s often used for shipping boxes.
• E Flute: This is the second-thinnest choice, at 1.6mm (1/16 inch). It saves space, making it great for packaging consumer goods.
• F Flute: The thinnest option, designed for stiff packaging applications

Strength Testing Methods

Two primary methods determine corrugated fiberboard strength:

Edge Crush Test (ECT): This test checks how much force a board can handle when pressure is put on the standing flutes. It simulates the strength of stacked boards. An ECT rating shows how many pounds a sample can support for each inch along its edge before it breaks. Standard Gaylord boxes have an ECT rating of 32. This means they can hold up to 32 pounds of force before they break or get punctured.

Burst Strength (Mullen Test): Tests how well a material holds up against pressure. It uses a diaphragm to push on the cardboard sample until it breaks. This test is especially important for packages with products that create internal forces. This includes small items that may move during shipping.

Rectangular vs. Octagonal Designs

Gaylord boxes come in two primary shapes: rectangular and octagonal. Each design offers unique benefits for different applications.

Design Differences and Benefits

The primary difference between rectangular and octagonal Gaylord boxes is their stacking ability. Octagonal boxes have four extra pressure points. This gives better and more even weight distribution than rectangular designs.

With rectangular Gaylord boxes, each wall must bear twice as much weight as the walls on an octagonal box. This difference might not greatly impact the weight capacity. However, it does influence the container’s strength and lifespan.

Octagonal Gaylord boxes usually last longer. They manage heavy loads effectively. This is because they spread structural stress across more contact points. Octabins have significantly better stacking ability than their rectangular Gaylord counterparts.

The octagonal design is stable because it has eight contact points when stacked. This is great for heavy loads and items that need even weight distribution.

Standards and Certifications

ASTM Standards

ASTM-D5118 is a standardization for fabricating corrugated fiberboard boxes and containers. The methods and practices show how to build corrugated boxes. These boxes are used for shipping products and parts in many sizes and shapes.

This standard covers details about:

• Corrugated material grades
• Adhesive needs
• Joint tab widths
• And more.

These specifications improve package protection against environmental conditions during shipping and storage.

UN Certification for Dangerous Goods

UN-certified packaging is approved by the United Nations. It ensures safe transport of hazardous materials or dangerous goods. These standards come from the UN Recommendations on the Transport of Dangerous Goods. Many countries around the world recognize and follow them.

UN certification proves the packaging is made and tested to meet strict standards. These include strength, durability, leakage prevention, and impact resistance. UN-certified packaging shows a UN symbol, a packaging code, and a performance or group code.

Forest Certification Programs

Companies that care about the environment can earn certifications for their corrugated products. These include the Forest Stewardship Council™ (FSC) and the Sustainable Forestry Initiative (SFI). Both international nonprofit organizations set strict standards for sustainable forest management. They certify that suppliers meet these standards.

FSC is a worldwide standard for responsible forestry management. It started in 1993 and has clear criteria. SFI started in 1994. It was created by the North American forest products industry. SFI checks that fiber comes from legal and sustainable sources. This is done through third-party audits.

ISO Certifications

Several ISO standards are particularly relevant for corrugated container manufacturers:

• ISO 9001:2015 – Quality Management System (QMS): It keeps quality steady at every stage. This starts with choosing raw materials and ends with delivering the final product.
• ISO 14001:2015 – Environmental Management System (EMS): This standard helps organizations lessen their environmental footprint. It ensures compliance with laws and promotes ongoing improvement in environmental performance.

Sustainability and Reuse

Gaylord boxes offer significant sustainability benefits in modern supply chains:

• Reusability: People often believe Gaylord boxes are for one-time use, but they can last a long time. You can buy and sell them multiple times. This reuse capability significantly reduces packaging waste.
• Resource Conservation: Using Gaylord boxes cuts down the need for new packaging. This helps save natural resources and lowers reliance on raw materials.
• Waste Reduction: Companies can reduce waste by reusing these strong containers. This also helps lessen their impact on the environment. Their strength allows them to last through many usage cycles without compromising functionality.
• Economic Benefits: Switching to reusable Gaylord boxes saves businesses money. This is in addition to the environmental advantages over disposable packaging.

End-of-Life Options

When Gaylord boxes are beyond repair, businesses should follow responsible recycling practices. Damaged boxes should be broken down and placed in designated recycling bins. You can repurpose these materials into new products. This helps cut waste and save resources.

Corrugated materials have the maximum recycling rate of any packaging materials used today. In 2017, about 92% of cardboard and containerboard made in the US were recycled.

Accessories and Additional Features

Liner Bags

Gaylord liners are big polyethylene liners. They go inside corrugated boxes, metal bins, and plastic or fiberglass containers. These liners protect the bottom and sides of the box. They are especially useful for shipping granular, powdered, or moisture-sensitive materials.

Specialized barrier foil Gaylord liners protect sensitive products from climate issues. This means you won’t need expensive atmospheric warehousing or drying. These liners shield products from moisture vapor, temperature extremes, odors, and UV light. Custom box liners fit any Gaylord size. They can be open-top or have filling spouts. This design helps with closed-system filling and cuts down sealing time.

Lids

Plastic Gaylord lids are strong and reusable. They cover bulk containers during transit or storage. DuraGreen plastic Gaylord lids are made to fit plastic Gaylord containers. These lids are made from high-density polyethylene. They measure 40.1″ x 48.1″ x 2.3″ and weigh about 15.5 pounds.

Common Applications

Gaylord boxes are versatile containers used across numerous industries for various purposes:

• Shipping and storing bulk intermediate materials for further processing or packaging
• Collecting and shipping materials for recycling and waste management
• Transporting loose parts, mixed small containers, granular materials, and powders
• Storing and shipping plastic pellets, regrind, and powder in the plastics industry
• Moving and storing large, bulky items or multi-piece shipments
• Transporting dry food ingredients and grocery or department store bulk displays

Some applications need inner plastic liners or bin bags. These protect contents, especially when shipping granular or powdered materials.

Comprehensive Specifications Table

Aspect	Details
Standard Size	48″ x 40″ x 36″ (length x width x height) – the most common Gaylord box size
Other Common Sizes	36″ x 36″ x 36″, 40″ x 40″ x 40″, 48″ x 48″ x 48″, 58″ x 42″ x 45″ (D-container), 42″ x 29″ x 25.5″ (E-container)
Common Base Sizes	36″x36″, 40″x40″, 40″x48″, 48″x40″, 48″x48″
Shape	Octagonal (most common) or rectangular
Wall Construction	Single-wall, double-wall, triple-wall, four-wall, or five-wall
Weight of Typical Box	Approximately 15 to 45 pounds, depending on wall construction and size
Weight Capacity	Ranges from about 65 lbs for single-wall to 4,000–5,000 lbs for heavy-duty, multi-wall boxes
Flute Types	A, B, C, E, and F flutes, varying in thickness from 0.8mm to 5mm
Strength Metrics	ECT (Edge Crush Test) and Burst Strength (Mullen Test)
Common Applications	Bulk storage, shipping, recycling, food transport, industrial materials handling
Sustainability	Reusable, recyclable, cost-effective alternative to plastic containers
2024 Price Range	Grade A: $15.50-$16.80, Grade B: $12.30-$13.40, Grade C: $10.00-$11.10 (varies by state)
Market Size (2023)	Global industrial bulk packaging market: USD 26.14 billion
Projected Growth	CAGR of 3.2% from 2024 to 2030 for industrial bulk packaging
Key Standards	ASTM D5118, UN packaging certification, ISO 9001, ISO 14001
Certifications	FSC, SFI for sustainable forest management