What is a Gaylord Box?
We tend to get a lot of questions about Gaylord boxes from people outside the industry. After all, they have a funny name, don’t they? A Gaylord box (named for the company that originally developed them) is a large pallet-sized, corrugated cardboard box used in the packaging of most types of bulk material. When you see watermelons in the large boxes at your local supermarket, you’re looking at a Gaylord box. They come in various sizes, shapes, wall thicknesses, and have different top/bottom options.
There are three basic types of Gaylord boxes …
- Rectangle (REC)
- Octagon (OCT)
- High Performance Tote (HPT)
… that all have these features:
- Size (length, width, height)
- Wall thickness
- Bottom & Top Type
- RSC (regular-slotted container)
- HSC (half-slotted container)
- Tray
- DI (drop-in)
Three Types of Gaylord Boxes
We all know what a rectangle (four sides) and an octagon shape (eight sides) is, but what does that have to do with boxes? Well, the shape gives them different levels of strength for different purposes. Octagon-shaped boxes (or octobins) tend to have higher strength at the corners because the weight is distributed over these extra corners. Rectangles tend to be easier to use and set up because they keep their shape better. They are also easier to fill and empty for most users. Your choice depends on what you are using the boxes for. If you are using machinery to fill or empty the box, then the shape may be a bigger factor.
Now let’s talk about HPTs: High Performance Tote (a registered trademark of TOTECO Packaging Company). This heavy-duty rectangle box has both top and bottom flaps. HPTs can range from four-to six- wall construction with optionable corner posts that help support stacking up to six high in freezer facilities and are designed for multiple uses. HPTs are specifically designed for use to store frozen vegetables when new. When deemed no longer useable in the freezer industry, they’re highly sought after for recycling commodities from plastics to metals. They are often deemed the “Cadillac” of used Gaylords due to the heavy construction and overall weight. These boxes are very rugged.
Sizes, Walls and Flaps of Gaylord Boxes
LWH: Our Gaylord boxes come in a wide variety of sizes. Because most Gaylords are placed on pallets to make it easier to move and stack them, the lengths and widths are typically the same as a standard pallet: 48” x 40”. There are some bigger and some smaller boxes as well, but 48” x 40” is the most common. Our box heights range from about 30” all the way up to 57”, with the most common box heights being 36”– 48”.
- Ranging from two to six walls, wall thickness is all about strength and vertical compression. To tell how many walls a box has, view it from the top and count the number of flutes (wave-shaped cardboard material) on the side of the box. If there is one flute, it is a single-wall, two flutes, double-wall, and so on. The bigger the number, the more corrugated fiberboard layers it has, making the box stronger and more resistant to vertical compression. You most likely don’t need to have the thickest walls. See our blog, What Size Gaylord Box do I need? for more information on choosing the wall thickness for your products.
Bottom and Top Types
A regular-slotted container (RSC) is any box that has four flaps the top and the bottom. One advantage here is there’s no need for a separate lid that can become lost. Used RSC boxes are commonly used in the recycling of various commodities and when new, are often used for shipping food ingredients. These boxes typically require tape on the flaps to secure them shut and can be made from one to five walls thick. If you need a box to ship a valuable product or wish to prevent viewing with wandering eyes and sticky hands, consider an RSC. It’s also a great box for providing protection from damage during shipment. This box is typically rectangular in shape.
A half-slotted container (HSC) is any box that has one set of flaps on the bottom, requiring a lid if the box needs to be sealed shut. this type is also known as a full-flap bottom. An HSC can have flange top to aid in extra rigidity for stacking. HSCs can be made from one to eight walls thick and are used in a wide variety of industries when new. Used boxes are often used in recycling industries or manufacturing that don’t require a new food grade box. Many users choose an HSC when using a poly liner or a lid. It’s available in both rectangular and octagon shapes.
A sleeve/tray/cap is any box that doesn’t have either top or bottom flaps. This style requires a separate tray for the box to sit into and a tray to cover the top as well. These can be made from one to six walls thick. This type of box is typically only useful for long-term storage or for industries that use them internally and ship them between locations. Otherwise, these are a one-trip, one-use option when a corrugated cap is used.
Full-flap octagons (sometimes called octobins) have bottom flaps that interlock and don’t require tape to secure. These can be made from one to five walls thick. This type requires a separate lid if sealing the box is necessary. Octagon boxes are often the primary choice for plastic companies who choose to use Gaylords to transport their resin or plastic additives. The extra surface points add extra strength for stacking. These are a good choice for many recycling commodities.
Partial-flap octagons (sometimes called modified bottoms) are typically a four-or or five-wall box that have partial flaps with locking tabs on the bottom that secure the box once it is erected. By having a partial flap on the bottom, these boxes require a separate sheet to cover the area in the center of the box left open by the short flaps. These boxes are mostly used in the plastics industry when new. They take up less space in a truck and are a more economical option than a full-flap bottom box. The added surface points add extra strength when stacking and is why this box is a common choice of many recycling streams.
Benefits of Gaylord Boxes
When you’re using Gaylord boxes, you are using a common packaging practice and an economical way of shipping materials from point A to point B. Your results are increased efficiency, cleaner material and cost savings.
Other benefits of Gaylords boxes:
- Self-supporting when being filled
- Eco-friendly because they are reusable and recyclable
- Durable, lasting for many years in storage at a minimal price compared to large plastic or metal bins
- Can be stacked in warehouses and double stacked in shipping containers to help maximize shipping and minimize costs
- Can also be helpful for brand awareness by customizing them with your images
- Many businesses that ship in Gaylords recoup some of the cost by charging consignees for the container, which in some cases are reusable to them: A win-win!
Helluva Container has more than eighteen years of experience serving customers from multiple warehouse locations in the U.S. and Canada with the highest level of service, product and cost savings. We think outside of the BOX to ensure that your specific needs/situation(s) are met to the best of our ability. Whether you need a single, small quantity or large multiple truckload orders, you have found the right company.
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