Gaylord Box
Guide
A working reference for gaylord box types, sizing, wall construction, and capacity — for buyers moving bulk product without going to an FIBC or drum.
What a gaylord box actually is
A gaylord box (also called a bulk box, octabin, or bin box) is a large corrugated container — typically built on a pallet-sized footprint — used to move and store bulk quantities of loose, granular, or irregularly shaped product without the cost or handling requirements of a drum or FIBC. Most are double or triple wall construction to handle the weight of bulk contents stacked several feet high.
- ABulk bin body — double or triple wall corrugated walls, typically sized to a 40" × 48" pallet footprint.
- BLid — separate flat or telescoping cap that fits over the top opening; some styles use flaps instead of a full lid.
- CPallet base — a wood or corrugated pallet permanently or semi-permanently attached to the bin for forklift handling.
- DLiner (optional) — a poly bag or film liner inside the box for moisture protection, dust containment, or food-grade contact.
Gaylord construction styles
Separate lid, full overlap
A separate lid that fully telescopes down over the top of the box body, similar to a shoebox. Best moisture and dust protection of the common styles.
Open top, flat cap or pad
Open-top box with no bottom flaps (sits on a pallet), typically closed with a simple cap or corrugated pad rather than a full telescoping lid.
Attached flaps fold to close
Flaps attached directly to the box body fold inward to close the top, taped or stapled shut. Lower cost, less reusable than a separate lid style.
8-sided, self-supporting
An eight-sided variant that's more self-supporting under load without a separate outer frame — common in plastics resin and bulk food ingredient handling.
Standard sizing & capacity reference
| Footprint | Height | Wall | Typical Capacity | Typical Use |
|---|---|---|---|---|
| 36" × 36" | 36"–40" | Double Wall | 800–1,200 lbs | Light bulk goods, recyclables |
| 40" × 48" | 36" | Double Wall | 1,200–1,800 lbs | General bulk product, resins |
| 40" × 48" | 40"–46" | Double Wall | 1,800–2,200 lbs | Standard industrial bulk |
| 40" × 48" | 36"–46" | Triple Wall | 2,200–3,000 lbs | Dense/heavy bulk material |
| 44" × 44" | 44" | Triple Wall | 2,500–3,500 lbs | Metal parts, dense minerals |
| 48" × 48" | 46" | Triple Wall | 3,000–4,000 lbs | Max-capacity bulk shipments |
Actual capacity depends on ECT rating and stacking conditions — see the Corrugated Board Grades guide for how ECT and wall count translate to real compression strength.
Liners & accessories
Poly liners are the most common gaylord accessory — a loose-fit or form-fit poly bag inside the box that protects against moisture, contains dust or fine product, and can make the box suitable for food-grade contact without treating the corrugated itself as food-grade.
Other common accessories include corrugated pallet bases (lighter and often less expensive than wood for single-trip use), top caps or pads for open-top styles, and banding to secure the lid during transit.
Gaylord vs. FIBC vs. drum
Solid, irregular, or mixed bulk
Best for parts, granular solids, or mixed-size scrap that doesn't flow like a powder — the rigid walls hold shape without needing the product itself to provide structure.
Free-flowing powders & granules
Better for product that flows and settles like a liquid — resins, sand, powders — where a flexible bag can be filled and discharged efficiently. See the FIBC Bulk Bag Guide.
Liquids, hazmat, small dense loads
Best for liquids, hazardous materials requiring UN-rated rigid containment, or smaller dense loads where a full pallet-sized bin is oversized.
Common questions
Are gaylord boxes reusable?
Some are, depending on construction and how they were handled — full telescope styles with a separate pallet base tend to hold up best for multiple trips. Most single-wall or taped-flap styles are intended for single use.
Do gaylords need a pallet underneath, or is the base built in?
Both exist. Many gaylords have a pallet base permanently attached for direct forklift handling; others are designed to sit on a separate standard pallet.
Can a gaylord be used for food product?
Yes, with the right liner — a food-grade poly liner inside a standard gaylord is common practice, since the liner (not the corrugated) is what's in direct food contact.
What ECT rating should I look for?
Depends on capacity and stack height — heavier bulk loads generally call for 48+ ECT double or triple wall. See the Corrugated Board Grades guide for how to match ECT to your weight and stacking needs.
Not sure which bulk container fits your product?
Tell us your product, fill weight, and how it flows — we'll spec the right gaylord, FIBC, or drum and quote it same day.