Our Gaylord boxes and FIBC bags are so tough, they’ve been known to send Chuck Norris running. But don’t get the wrong opinion, our packaging is tough…but friendly.
The story of our business is one of courage, humility, and a little bit of magic. When our founders, Ben Baldwin and Kevin Connelly, launched Helluva Container in 2003, the bulk container market was conspicuously underserved...at least as far as quality was concerned. So, when they decided to fill the niche, the two were venturing into some uncharted territory.
What quickly established Helluva Container as a leader was Ben and Kevin’s obsessive commitment to service, support, speed and loyalty. They established practices and a culture that today outperform all others in the packaging industry.
Box. Bag. Believe. Videos
> > The League
In a world with an insatiable appetite for reliable Gaylord boxes, one covert agency has quietly maintained an uncompromising devotion to Gaylord box reliability. And they happen to work for us. Their tradecraft has remained a closely guarded secret. Until now.
Discover the mysteries of Helluva’s Box Restoration League. And discover a level of quality unmatched anywhere. Click now to watch.
> > Trust in the Bag
What would you be willing to risk to prove the strength of something you believed in? How far would you go to earn someone’s trust in that something? Watch Helluva Container put it all on the line with one our FIBC bulk bags. And then decide if we went too far.
Get ready to put your Trust in the Bag. Watch now.
> > Uncontainable
Even though the people of Helluva Container are devoted to you in a way no other partner is — through the good times and the bad, whether you’re a dog person or a cat person, or whether you think it’s a to-MAY-to or to-MAH-to — there’s only one thing our FIBC bulk bags and Gaylord boxes can’t handle.
WE SPECIALIZE IN HIGH QUALITY NEW AND USED GAYLORD BOXES,
FIBC bulk bags, liners, films, tapes and pallets. With distribution centers all across the United States, Helluva Container always has inventory ready to go.
More importantly, our people are devoted to making your life easier – by taking bulk container logistics off your plate – so much so that we procure, stock and manage your packaging needs to help you get ready well before the rush that might wipe out other managers less crafty than you.
To see these packaging geniuses talk about what makes us a Helluva Company,
check out the corporate video.
Gaylord Box Types
Box Type: Rectangle / Octagon / HPT
Material Type: Corrugated / Single-Double-Triple Wall Thickness
Condition: New / Used
Open Top / Full Flat Bottom Rectangle
This box is open at the top and has four full flaps on the bottom. Shown with optional lid.
Full Flap Top & Bottom Rectangle
This box has four full flaps on the top and the bottom.
Flange Top / Full Flap Bottom Rectangle
This box has four flanges on the top and four full flaps on the bottom. Flange top boxes can be closed by putting a top cardboard sheet under the flange and strapping the box.
Open Top / Full Flap or Drop-In Bottom Octagon
This box has eight sides with an opening at the top. The bottom has either four full flaps or is a drop-in with a pad.
UN approved packaging is a designation for packaging that has been built, tested, and certified to carry liquid or solid dangerous materials. To ensure the safe and secure transport of such materials, the Department of Transportation implemented this shipping method for certain chemicals listed in 49CFR (Code of Federal Regulations – Transportation). By utilizing UN approved packaging, properly marked and used in accordance to the manner it was tested and intended, there is greater assurance that these particular dangerous goods are packed to prevent spillage or loss.
UN approved packaging is also known by the following terms: hazmat packaging or hazardous materials packaging, type-approved packaging, dangerous goods packaging, UN packaging, UN certified packaging, performance oriented packaging (incorrectly termed "POP packaging"), chemicals packaging, paint packaging, infectious packaging, and DOT approved packaging.
Balcon Enterprises, Inc. can provide UN approved packaging through custom orders, we do not stock UN Certified bags.
A duffel top is typically a 30" high "skirt" sewn to the top of a bulk bag. The duffel usually comes with a tie allowing the user to secure the duffel closed, at the same time allowing the user full access to the product.
A standard fill spout is a spout with a 14" diameter opening in the top (center) of the bag, usually 18" long. It's designed to allow the user to fill the bag, minimizing dust occurrences as the bag is being filled. The length of a standard fill spout is 18" long. Spouts can be customized to fit an individual application.
Lift loops are the means by which a forklift raises the bag with its forks. In other words, they are loops attached to the 4 top corners of the bulk bag to enable a fork truck operator to put the fork in and lift the bag. Standard lift loops are 10" but can be customized to any workable size.
Typically documents are attached by use of a document pouch, which is usually a 10x12 polyethylene bag sewn to the seam of the bulk bag. A document pouch can have ziplock opening, or a standard opening and can be sewn where the users prefers.
Baffles are pieces of fabric that are sewn to the inside corners of a bag to maintain its cube shape after filling. The baffles have holes that allow the product to flow freely through them. The baffles also prevent the bag from bulging, which makes the bag stand up straight and in turn allows the bags to be more efficient in their use of space.
A B-lock is a spout accessory designed to assist in the closure to the spout. It is a quick and easy way to close a spout, manually regulating the flow of product. The device locks quickly and easily, and replaces the normal tie usually sewn to a spout.
UV Protection is an additive that is added to the resin during the extrusion process. It will assist in protecting the bulk bag from the harmful affects of UV rays, thereby protecting it from degrading and becoming unstable and unsafe.
Yes, but bulk bags will degrade as a result of UV exposure. A standard bulk bag has a UV inhibitor added into the fabric at the manufacturing level. Manufacturers add enough UV inhibitor to resist UV rays for approximately 1600 hrs. Although this is dependent upon where the actual bag is located on the globe. In other words, UV rays vary in strength and degree in different parts of the world.
There are several styles of stitching used when sewing a bulk bag. Chain and Overlock stitching are two of the most common styles used. Chain stitching is series of looped stitches forming a chain-like pattern. Overlock stitching sews over the edge of two pieces of fabric. Many manufacturers use this style of stitching to assure a tight seam, which assists in reducing sift occurrences.
Type A – plain coated fabric, no static protection–Used with non-flammable products.
Type B – uncoated fabric or fabric with thin coating and with breakdown voltage < 6 kV–Used with less sensitive flammable powders.
Type C – interconnected conducting yarns, resistance to ground < 108 W–Used with flammable powders and where flammable solvents are present–MUST BE GROUNDED (very dangerous when grounding fails).
Type D – quasi-conductive yarns, not interconnected – does not require grounding–Used with flammable powders and where flammable solvents are present–Safe replacement for Type C.
The Flexible Intermediate Bulk Conntainer Association (FIBCA) was formed in 1983 by the companies that were manufacturing bulk bags at the time. There was a need for a single voice in dealing with the regulatory bodies that controlled the shipment of products. FIBCA today is the source of information to its members on regulations for international shipments of product.
When selecting and FIBC, one needs to consider the Safe Working Load (SWL) and Safety Factor (SF) for your packaging needs. SWL is the total weight that the bag is tested and related to hold safely. The SF is the number of times the FIBC can hold above the total SWL while in resting position on the ground. A standard bulk bag is rated at a 5:1 Safety Ratio, which means that the bag is specified to hold 5 times the amount of the bags safe working load. A 5:1 Safety Ratio is for single use or single trip bags. Bags that are designed for multi-use or multi-trip bags, are made with an increased SF ratio. The SF for a multi-trip bag is 6:1.
Quality is fundamental and our Manufacturing Partners have an in house Quality Assurance system of auditing performance, ensuring that the customer is supplied to specification. All locations are certified with ISO 9001-:2008 and are BRC accredited.
Although polypropylene is one of the strongest man-made fabrics available, just like rigid bulk containers, FIBCs can be damaged if carelessly handled. It is important that your equipment is regularly checked. For example, forklift truck tines with rough edges may damage the FIBC. If handled correctly, FIBCs can be used successfully for many trips.
When properly filled with most products, FIBCs can be stacked in a warehouse 2 or 3 high. The stability and height of the stack is dependent on the product together with the handling equipment available. It may be preferable to stack 'pyramid' style depending on the stability of the product itself. Please make sure you consult your bulk bag representative when discussing bulk bag stacking.
If you are putting new product into a bag, we do not recommend the use of second hand bags. If you do use second hand bags, be sure that you use a company that has knowledge of the bag’s previous contents and can demonstrate what processes they put in place to recondition the bag. Keep in mind all second hand bags are used and you need to inspect each bag for rips, holes, tears before using. All second hand bags are use at your own risk.
A ‘Gaylord’ box can also be known as a bulk bin, pallet box, skid box, octobin, tote or even monster. The origin of the term ‘Gaylord’ comes from a company that started out in the 1920s making patented large boxes, the Gaylord Container Corporation. Although the company has had multiple owners and many different businesses now manufacture these boxes, the name of the containers still represents the man who patented and invented them. It’s similar to the term ‘Kleenex’ being used generically to describe all facial tissue.
The ‘Flute’ describes the arrangement of the wave-shaped cardboard material that makes up a box’s corrugation. Flutes are basically the reinforcement that makes up the cardboard. They run parallel to the depth of the container and give it its stiffness and crushing/stacking strength. Flutes also provide insulation that protects products from sudden temperature changes.
Flutes come in several sizes, known as flute profiles. The standard profiles range from A-flute (the largest) to F-flute and below (microflutes). Typically, larger flutes provide greater strength and cushioning, while smaller flutes have better printability and foldability. For double-wall and triple-wall boxes, the flute sizes for each sheet of corrugated material are usually different. This method combines their advantages, and prevents any weakness that might result if the flutes were perfectly aligned.
Looking from the top of the box, count the number of flutes on the side of the box. If there is 1 flute, it is a single wall, 2 flutes, double wall, and so on. Most resin boxes have between 3 to 5 walls.
We buy most styles of Gaylord boxes. The most important thing we look at is condition of the box, quantity offered, frequency and proximity to our processing centers. Most of our customers re-use our boxes multiple times so we need boxes that are still in good shape. Not beat up or cut up and can still maintain their shape. If you have excess boxes that you would like to sell, please feel free to call us at any time 877-745-0311.
The unprocessed boxes come to us bundled so the first thing we do is blow the bundles off with an air hose to get any dust or dirt off them and begin sorting into our part numbers according to size, shape and tops and bottoms. As we are sorting we visually inspect the boxes for any damage such as holes, damaged flaps, and broken seams. When we encounter these we repair them with high quality tape otherwise we must discard them. During sorting we are also “cleaning up” the boxes. This includes: pealing excess tape from previous users, pealing old labels or stickers, blowing off dust and debris and emptying any previous contents out. Once the boxes have met our high standards they get stacked, bundled and then entered into our live inventory system.
We buy boxes from many different industries. Some of our boxes come from the plastics industries and have previously held resin. Other boxes are bought from different food companies and may have contained raw ingredients such as: wheat, peanuts, noodles, and frozen vegetables. If you need more info on specifically what was in the box you ordered please ask.
Not all of our boxes are shipped on pallets. This depends on the customer’s request. The customer may not have the equipment to unload a delivery on pallets. They may not have a floor jack or the needed equipment. This information is determined at the time of order and is noted on the permanent record.
The biggest difference between them is the shape, obviously. 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 distributer over these extra corners. Rectangles tend to be easier to use. They are easier to set up because they keep their shape better. They are also easier to fill and empty for most users. With that being said it really depends on what you are using the boxes for. If you are using machinery to fill or empty the box then shape may be a bigger factor. Usually the bigger factor is what kind of top or bottom you need. But that is for another article.
We do have a program that allows us to work with our customers to create a custom Gaylord box that perfectly fits their needs. However, this usually comes with a minimum order requirement based on size and cost of the box.
The quick answer No. Helluva is a registered trademark of Balcon Enterprises Inc. and we are using that name for our industrial products. Why do you ask? We have been to a lot of customer sites where our products are being used and heard that’s a Helluva box or that’s a Helluva bag so many times, that with the help of a marketing company from Minneapolis we decided to register the name and use it in our packaging products. Those words at the customer’s premise is due years of a behind the scenes work, product development and systems implementation. We do not take what we do lightly and want to make sure that what we send to our customers are safe, reliable and a Helluva product.
Because we’re Helluva good, that’s why. We’ve been in business a long time and we’re experts in industrial packaging. We have six warehouse locations placed strategically throughout the country to best service customer needs and reduce shipping time and cost. Since we ship everything from one of our own warehouses, we’re able to control the quality of the product you receive, thus ensuring a Helluva product load after load!
Depending on the product and location, once it leaves our warehouse, most items deliver in 1 -5 days. In stock items usually ship same day if order is placed early enough and freight carriers are available. Custom order bulk bags will take 12-14 weeks. Custom order boxes are 3-4 weeks.
Balcon can send samples of new boxes direct to the customer. This is a timely process as these are all custom made and generally requires a PO in place for an order to be placed if the boxes are received as described. The same goes for new bulk bags. Used boxes and bags samples can be attained if the customer agrees to pay for shipping these samples at their own expense. An account must be established in order for any samples to be sent out. Samples of used items are subject to inventory at the time of request.
This is a question that you may want to discuss with an expert directly at Balcon with as there are multiple factors that go into this equation. It is best understood that empty bulk bags take up less space in a warehouse but loaded bulk bags can not be stacked as easily as loaded Gaylord boxes. So it all depends in your application.
Balcon does have a satisfaction guarantee based on how the product was described to the customer at the time of the sale. If it is a new product and it has manufacturers defects you will either be credited for the defective product or we will see that this product is replaced in a satisfactory time. We will do whatever means necessary to correct the issue in a cost effective and timely manner.
This is a complicated subject and is discussed in depth on our blog. If you are not accustomed to provisioning freight, you might let us take care of it for you. We have been at it for a long time.
The price at which product is moved from one location to another is known as a freight rate. While there are many ways to calculate freight – due to the many ways product is moved (air, land, and sea) – we’ll focus on how to calculate land freight. Likewise, weight or volume, distance, handling and clearing charges, administrative fees from carrier, and the class assigned to the cargo.
To calculate freight you will need the length, width, height, and weight of the item or items to be shipped. For example, you wish to ship a pallet 40” in length, 48” in width, 48” in height, and 425 pounds in weight. Vol (cubic feet) = lwt/1,728 = 40*48*48 = 53.33; wt=425 lbs. Density = wt/vol = 425/53.33 = 7.97 cu ft. Freight class is based off of weight range per cubit foot; therefore 7.97 cu ft would correspond with Class 125. Using this Class, along with some other considerations that I list below, the freight carrier will calculate your freight cost.
In some cases weight or volume can be controlled. Reducing either of these factors may help reduce the freight cost by affecting the freight class*.
Costs associated with the distance traveled may be controlled by choosing a carrier that has a well-established supplier connection.
Handling, clearing costs and administrative fees will vary carrier to carrier. A good search of carriers may provide a carrier with low fees for these activities but cheaper may not always be better.
Freight class is determined mainly by (weight, length, height) density and value but can also be affected by the following:
Does the product require specific transportation practices (such as hazardous materials)?
Is the product excessively heavy or large and/or oddly shaped?
Does the product require special handling attention (as would be expected with hazardous materials)?
Does the product create additional liability to the carrier (in the sense of perishable cargo or priceless cargo that could be susceptible to theft)?
*Freight Classes are defined by the National Motor Freight Traffic Association (NMFTA) and are made available through the NMFC (National Motor Freight Classification). In order to give customers a uniform pricing structure for freight, the NMFC assigned a class – ranging from 50 (cheapest) to 500 (most expensive) – to each commodity or type of product. Since these class assignments help determine tariff costs, they are important to freight carriers when calculating your freight cost.
A pallet jack is a tool used to lift and move heavy pallets (two-way only) or materials around your warehouse. There are manual and motorized types of pallet jacks. A manual pallet jack is ideal for warehouses where pallets are mainly stored at ground level. If you are storing pallets in pallet racks or stacked in layers of two or more, motorized pallet jacks are a better solution due to the extra lifting power and stabilization provided by a motor. Unlike forklifts, pallet jacks are built for an indoor facility, rather than indoor and outdoor use. They can also be known as jigger, hand jack, walkie, pump truck and pallet truck.