Summary: Pallet-sized bulk containers —also called Gaylord boxes— are double or triple-wall corrugated cardboard containers placed on pallets to safely move and store bulk product. They are reusable, recyclable, and optimize handling with a pallet jack or forklift.
What is a pallet-sized bulk container (Gaylord)?
The term "Gaylord" comes from the original manufacturer, Gaylord Container Company in the USA, and is now used to refer to any large-capacity corrugated cardboard container designed to be placed on a pallet. These boxes may include:
- Separate base and lid for greater stability and content access.
- Sleeve or lateral band that forms the walls.
- Closing flaps that allow securing the contents from above.
They are generally made with double or triple walls, offering different levels of resistance depending on the load. If you want to understand the differences between types of cardboard, consult our corrugated cardboard guide.
Main advantages
Logistical efficiency and ease of handling
These boxes are easily moved with a pallet jack or forklift, reducing loading and unloading times. By going directly onto the pallet, you eliminate the need to pack each piece separately — you put all the bulk product in, strap it, and you're done.
Protection and stacking resistance
Double or triple-wall corrugated cardboard withstands high pressures, allowing several loaded boxes to be stacked without risk of collapse. Resistance is measured with ECT and BCT tests — if you want to understand how they work, we explain it in our article on corrugated cardboard. To reinforce the corners and prevent stretch film from cutting the edges, add cardboard edge protectors.
Sustainability and recycling
Cardboard is 100% recyclable in the blue bin and has one of the highest recovery rates in the packaging sector. A cardboard Gaylord box is significantly more environmentally friendly than an equivalent rigid plastic container.
Space saving and quick assembly
Boxes are delivered flat-packed, occupying a fraction of the space they would need when assembled. They can be assembled in a few minutes without special tools. When you no longer need them, they can be folded again or recycled directly.
Measurements and pallet compatibility
| Pallet type | Pallet size | Recommended box size | Notes |
|---|---|---|---|
| Euro pallet (EUR/EPAL) | 1200×800 mm | 80×60×55 cm | 2 boxes complete one pallet. Leave 1-2 cm margin for strapping and edge protectors |
| Industrial/UK pallet | 1200×1000 mm | 100×80 cm (base) | Allows wider bases for more volume |
Usable height: consider the total height including lid + strapping + edge protectors, and the clear height of the transport vehicle. For standard trucks, the interior height is usually 240-270 cm — calculate how many boxes you can stack without exceeding that measurement.
How to prepare a Gaylord box for shipping
Assembling and preparing a large pallet box has its peculiarities. These are the steps to ensure safe cargo:
- Assemble the box on the pallet — make sure it does not protrude on any side. Leave a 1-2 cm margin.
- Place the product inside — distribute the weight evenly. Heavy objects at the bottom, light ones at the top.
- Close the lid or flaps — use reinforced tape of 75 mm for secure closing.
- Place edge protectors on all 4 vertical corners — they protect the edges and provide structure. Consult our guide on cardboard edge protectors.
- Wrap with stretch film — minimum 3 wraps at the base and spiral up, overlapping 50%. We have a complete guide to stretch film and a guide to palletizing.
- Strap if the load is heavy — strapping adds an extra layer of security for loads over 200 kg per pallet.
Frequently asked questions about Gaylord boxes
What does "Gaylord box" mean?
It is a generic term referring to a large format corrugated cardboard box designed to be placed directly on a pallet. The name comes from the original manufacturer Gaylord Container Company. In Spain, they are also called "pallet boxes", "container boxes" or "trunk boxes".
What is the capacity of a pallet-sized box?
It depends on the size. A format of 80×60×55 cm (half Euro pallet) has a capacity of 264 liters. A box that covers the entire Euro pallet at the same height would have about 528 liters. You can calculate the exact volume with our online tool.
Can I stack several loaded Gaylord boxes?
Yes, as long as the cardboard's resistance (BCT value) and the maximum recommended weight are respected. With double-wall cardboard and edge protectors on the corners, you can safely stack 2-3 levels of loaded boxes. Consult the box's technical sheet to know its stacking limit.
Are Gaylord boxes reusable?
Yes. If handled correctly (without getting wet, without overloading, without damaging the edges), they can be reused multiple times. Double and triple-wall cardboard is especially resistant to repeated use.
How do I know if my box is compatible with the pallet?
The base of the box should not protrude from the pallet on any side. It is advisable to leave a 1-2 cm margin on each side to place edge protectors, strapping, and stretch film. For Euro pallets (120×80 cm), 80×60 cm boxes are the optimal format.
Where to buy large pallet-sized boxes in Spain?
At TeleCajas, they have large format double-wall cardboard boxes, compatible with Euro pallets. Shipping in 24-48 hours throughout Spain and Portugal. For bulk orders or special sizes, request a personalized B2B quote.
Featured recommendation
Giant Double-Wall Cardboard Trunk Box 80×60×55 cm — TeleCajas
Approx. volume: 0.264 m³ (264 L) • "Trunk" format • Compatible with Euro pallet
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