A Guide to Gaylord Boxes

If you’ve ever seen a big, sturdy cardboard box sitting on a pallet at a grocery store, thrift shop, or warehouse, chances are it was a Gaylord box. These heavy-duty boxes are used to hold and move large amounts of stuff, like watermelons, used clothes, or scrap metal. They’re strong, affordable, and super useful for businesses.

In this guide, we’ll explain what Gaylord boxes are, why they’re called that, and how they became so popular.

What Is a Gaylord Box?

A Gaylord box is a large cardboard box made from corrugated cardboard material (that’s the kind with the wavy layer inside). It’s designed to hold and transport big, heavy loads. These boxes usually sit on pallets, making it easy to move them with forklifts or pallet jacks.

They’re known by other names too, like:

• Bulk bins
• Pallet boxes
• Tote boxes
• Octabins

Whatever you call them, they’re basically big, heavy duty boxes made to carry a lot of stuff.

Why Are They Called Gaylord Boxes?

It is sort of an odd name when first hearing it. The name “Gaylord” comes from the Gaylord Container Corporation, which was eventually acquired by International Paper

This company that helped make these boxes a staple in shipping and storage. The 1980s were a tough time for the paper industry. Prices for paper plummeted, mills were producing more than they could sell, and many companies were struggling to stay afloat. The Gaylord Container Corporation had to get creative to survive.

Faced with these challenges, the company introduced a new kind of bulk container: a corrugated cardboard box that was lighter and cheaper than wooden crates but still strong enough to handle heavy loads. This innovation came at a time when businesses were desperate for cost-effective solutions. The design quickly gained popularity, and soon, the name “Gaylord box” became synonymous with these large, durable containers. Even today decades later people are still calling these bulk cardboard boxes "gaylords".

This period also saw a shift toward sustainability. With growing environmental awareness, companies were under pressure to reduce waste and adopt greener practices. The corrugated Gaylord box fit perfectly into this new mindset—it used less material, could be recycled, and offered a practical way for businesses to cut costs while staying eco-friendly. The success of the Gaylord box wasn’t just about surviving a tough economic period; it was about setting a new standard for efficient, sustainable packaging.

What Are Gaylord Boxes Made Of?

Gaylord boxes are made from corrugated cardboard, which is much stronger than regular cardboard. Also know as PLY or Walls, The more layers the box has the stronger it is.

Common Types of Gaylord Boxes

Beyond the wall types, Gaylord boxes also vary in design based on their purpose:

HTP-41 Boxes:
These are standard four-wall Square Gaylord boxes often used in agriculture and recycling. They’re designed to fit on a 48” x 40” pallet and can hold a wide range of goods.

Octagonal Boxes (Octabins):
These eight-sided boxes are great for added stability and are commonly used for shipping irregularly shaped or lightweight items like grains or foam. Very common in the plastic recycling industry

Common Sizes of Gaylord Boxes

Gaylord boxes come in a variety of sizes to fit different applications. Here are a few of the most popular:

Standard Size (48” x 40” x ”)

• Fits on a standard pallet.
• Great for general-purpose use, like produce or recycling.

Large Size (48” x 40” x 48”)

• Offers more vertical space for bulky loads.
• Perfect for items like foam, fabric scraps, or large recyclables.

Half-Gaylord (48” x 40” x 24”)

• A shorter version for smaller loads.
• Commonly used for produce

Custom Sizes

• Many manufacturers offer custom dimensions to suit specific needs.

What Are Gaylord Boxes Used For?

Gaylord boxes are incredibly versatile and used in a wide range of industries. Here are some of their most common applications:

• Agriculture: Farmers use them to ship large quantities of produce, such as watermelons, potatoes, and onions.
• Recycling: Recycling facilities use Gaylord boxes to hold paper, plastic, metals, and even electronic waste.
• Retail: Thrift stores and bargain shops use these boxes to display items for customers to sift through.
• Manufacturing: Factories rely on Gaylord boxes to store and transport raw materials, like scrap foam or metal parts.
• Event Cleanup: Perfect for collecting large amounts of trash, recyclables, or donations after community events.

Final Thoughts

Gaylord boxes might seem like just big cardboard boxes, but they’re so much more than that. They’ve been a game-changer for industries that need affordable, durable, and eco-friendly solutions for shipping and storage.

Whether you’re a farmer shipping fresh produce, a recycler collecting scrap materials, or a retailer displaying thrifted goods, Gaylord boxes are a simple yet powerful tool that gets the job done.