What Is a Gaylord Box? Sizes, Dimensions & the Liners That Fit

A gaylord box is a pallet-size corrugated bulk box used to store and ship loose goods in bulk: produce, resin pellets, parts, scrap, recyclables and meat. The standard gaylord is 48" x 40" x 36", sized to sit on a standard 48" x 40" pallet, and heavy-duty versions are rated to carry 1,500 lb or more. Below: the common sizes and inside dimensions, how much they hold, and which gaylord liner fits each one.

What Is a Gaylord Box?

A gaylord is a large double- or triple-wall corrugated box that sits on a pallet and holds anywhere from a few hundred pounds to a ton or more of bulk product. You'll also hear them called pallet boxes, bulk boxes, bulk bins, pallet bins, skid boxes, bin boxes or totes, and the eight-sided version an octagon bin, octabin or watermelon bin. They're filled by forklift or by hand, moved as one unit, and often lined with a poly liner to keep product clean and dry or to hold powders, wet product and food.

How gaylord boxes are built

• Walls: double- or triple-wall corrugated. Triple wall carries heavier loads and stacks better.
• Bottoms: full-flap bottoms (the flaps meet) are the strongest; partial-flap bottoms need a slip sheet underneath; some gaylords are a sleeve that sits on a separate tray.
• Other materials: reusable plastic, wood and steel bulk containers do the same job; plastic ones have thick walls, so they're smaller inside than their outside size suggests.
• Reuse: most corrugated gaylords fold flat for return shipping or recycling.

Why is it called a gaylord?

The name comes from the Gaylord Container Corporation, formed in 1937 when Robert Gaylord, Inc. of St. Louis merged with the Bogalusa Paper Company. The company made large boxes for bulk goods on pallets, and its name stuck to the box.

Gaylord Box Sizes and Dimensions

Inside vs. outside dimensions: heavy triple-wall walls are about ½" thick, so a gaylord sold as 48 x 40 x 36 by its outside size is only about 46¾ x 38¾ inside. Double-wall boxes are often sold by their inside size. Sellers label this inconsistently, so measure the inside of your box (or check the spec sheet) before choosing a liner.

Gaylord Boxes We Supply

Need the boxes too? We supply gaylord boxes by quote and can quote the box and the liner together, so the liner is sized right from the start.

Matching lids are available for every size, and triple-wall corrugated sheets for slip sheets and pallet tops. Gaylords ship flat in bundles, so freight depends on quantity and destination: request a quote with the size, wall, quantity and your ZIP code.

Gaylord Liners: Which Size Fits Your Box

Gaylord liners are large gusseted poly bags, sized width x gusset x length. When the gussets open, the liner forms a rectangle as wide as its face and as deep as its gusset, so the width and gusset should be at least the inside length and width of the box. The liner stands about its length minus half the gusset, and whatever is left hangs over the rim. There are two ways to use it:

• Fold over the rim: the liner lines the box and folds 6" to 18" over the top edge. The shorter, lower-cost choice for dry product that stays open.
• Close over the top or tie shut: a longer liner gathers over the load and ties, tapes or folds closed, which keeps out dust, moisture and pests and holds powders and wet product. This is how most food, produce and resin shippers use them.

Overhang is approximate: liner length minus half the gusset minus the box height. How much you need to tie a liner shut depends on how full the box is. Need something in between? Two popular sizes for standard 48 x 40 gaylords, 48 x 42 x 78 and 48 x 42 x 90 in 1 mil clear or blue, are available by quote. Browse every size in our gaylord and combo liners, or cover the whole loaded box with a pallet cover.

How to measure your gaylord

1. Measure the inside length, width and depth of the box (not the outside).
2. Choose a liner whose width is at least the inside length and whose gusset is at least the inside width.
3. Add the overhang you want to the box depth: about 6" to 18" to fold over the rim, or roughly 30" to 40" to close a full box over the top.
4. Between sizes? Go up a size, or ask us for a custom size.

How thick should a gaylord liner be?

• 1 to 1.5 mil: light, dry product and dust protection; the most economical per liner.
• 2 mil: the everyday gauge for produce, parts, resin and general bulk storage.
• 3 to 4 mil: heavy loads, sharp or abrasive parts, wet product and liners that get handled a lot.

Clear or blue, and food contact

Clear liners let you see the product. Blue liners stand out against food, so a torn piece is easy to spot, which is why many meat and food plants use them. Our gaylord and combo liners are made from polyethylene that meets FDA requirements for food contact; see each product for details. For cartons and cases rather than gaylords, see our box liners.

How Much Weight Can a Gaylord Box Hold?

It depends on the box's construction, so check the rating printed on yours. As examples from one major manufacturer's spec sheets, a 48 x 40 x 36 triple-wall gaylord (1,100 lb test) is rated for about 1,500 lb, a 48 x 48 x 36 for about 1,400 lb, and a triple-wall octagon bin for 2,100 to 2,200 lb. Published figures vary a lot from site to site for two reasons:

• Wall counts aren't standardized. One seller's 3-wall is another's 4-wall, so compare the test or ECT rating instead.
• Shipping limits vs. bulk ratings. Box ratings of 100 to 300 lb you may see are carrier limits for a single box shipped by itself, not what the box holds full on a pallet.

Gaylord Bags vs. Bulk Bags

"Gaylord bag" usually means a poly gaylord liner like the ones above. It's different from a bulk bag (FIBC or super sack), a woven polypropylene bag with lifting loops that holds product on its own, without a box.

Gaylord Box FAQ

Is a gaylord the same as a bulk bin or pallet box? Yes. Gaylord, bulk box, bulk bin, pallet box, pallet bin and skid box are all names for the same pallet-size bulk box; an octabin is the eight-sided version.

What size lid fits a 48 x 40 gaylord? A lid is a little larger than the box's outside size: about 49½ x 41½ for a 48 x 40 gaylord. We supply lids with the boxes by quote.

What size is a standard gaylord box? 48" x 40" x 36" outside, made to fit a standard 48 x 40 pallet. Triple-wall versions are about 46¾" x 38¾" inside.

What size liner fits a 48 x 40 x 36 gaylord? A 48 x 46 x 72 liner folds about 13" over the rim. To close or tie the liner over a full box, use a 54 x 44 x 96 or 48 x 46 x 96.

What liner fits an octagon gaylord? Octagons are about 46 x 38 inside, so they take the same liners as a standard gaylord: 48 x 46 x 72 to fold over, 48 x 46 x 96 or 54 x 44 x 96 to close.

How thick should a gaylord liner be? 2 mil for most uses; 1 to 1.5 mil for light, dry product; 3 to 4 mil for heavy, sharp or wet loads.

Can a gaylord hold liquids or powders? Powders, yes, in a poly liner closed over the top. Liquids need a sealed liner made for the purpose or a container built for liquids, such as an IBC tote. Shipping hazardous materials in bulk boxes is regulated, so check the rules for your product.

Do you sell gaylord boxes? Yes, by quote: standard, tall, half-height, square, half-size and octagon gaylords in single, double or triple wall, with lids, plus the liners that fit them. Request a quote.