Gaylord Box Size Guide
Complete dimensions, specifications, and selection guide
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How to Measure a Gaylord Box
Understanding L x W x H dimensions for accurate ordering
Length (L)
Measure the longest side of the box opening, parallel to the flaps. For boxes on pallets, this typically runs front-to-back when facing the pallet.
Tip: Always measure inside dimensions for accurate capacity calculations.
Width (W)
Measure the shorter side of the box opening, perpendicular to the length. This dimension runs side-to-side when facing the pallet.
Tip: Width affects pallet fit - verify pallet compatibility before ordering.
Height (H)
Measure from the bottom interior of the box to the top of the side walls. Do not include flap height in this measurement.
Tip: Consider stacking height limits and forklift clearance.
Wall Thickness
For capacity planning, note that external dimensions are 0.5-1" larger than internal dimensions depending on single, double, or triple wall construction.
Tip: Heavy loads require thicker walls - factor this into space planning.
Important Measurement Notes
- • Box dimensions are listed as interior dimensions unless noted
- • External dimensions are 0.5-1" larger depending on wall thickness
- • Flap height adds approximately 3-6" to total collapsed height
- • Always measure your pallet first to ensure proper fit
Standard Gaylord Sizes
Most commonly requested dimensions - all in stock
| Dimensions (L×W×H) | Interior | Volume | Pallet Size | Max Weight | Common Use |
|---|---|---|---|---|---|
| 40" x 48" x 24" | 39" x 47" x 23" | 27 cu ft | Standard 40x48 | 2,000 lbs | Short items, electronics |
| 40" x 48" x 30" | 39" x 47" x 29" | 33 cu ft | Standard 40x48 | 2,200 lbs | Medium height products |
| 40" x 48" x 36"Popular | 39" x 47" x 35" | 40 cu ft | Standard 40x48 | 2,500 lbs | General purpose - most common |
| 48" x 40" x 36"Popular | 47" x 39" x 35" | 40 cu ft | Standard 48x40 | 2,500 lbs | Alternate orientation |
| 48" x 48" x 36"Popular | 47" x 47" x 35" | 48 cu ft | Square 48x48 | 2,800 lbs | Square footprint applications |
| 40" x 48" x 42" | 39" x 47" x 41" | 47 cu ft | Standard 40x48 | 2,800 lbs | Taller items |
| 40" x 48" x 48"Popular | 39" x 47" x 47" | 53 cu ft | Standard 40x48 | 3,000 lbs | Maximum volume standard |
| 48" x 40" x 48" | 47" x 39" x 47" | 53 cu ft | Standard 48x40 | 3,000 lbs | Alternate tall orientation |
| 48" x 48" x 48"Popular | 47" x 47" x 47" | 64 cu ft | Square 48x48 | 3,200 lbs | Maximum volume square |
| 45" x 48" x 42" | 44" x 47" x 41" | 53 cu ft | Custom 45x48 | 2,800 lbs | Specialty applications |
| 44" x 44" x 40" | 43" x 43" x 39" | 42 cu ft | Square 44x44 | 2,600 lbs | Euro pallet compatible |
| 32" x 40" x 30" | 31" x 39" x 29" | 22 cu ft | Half pallet | 1,800 lbs | Smaller operations |
Heavy Duty Sizes
Reinforced construction for heavy loads up to 5,000 lbs
| Dimensions | Wall Type | Weight Capacity | Volume | Best For |
|---|---|---|---|---|
| 40" x 48" x 36" | Double Wall (BC) | 3,000 lbs | 40 cu ft | Heavy parts, metal components |
| 40" x 48" x 40" | Double Wall (BC) | 3,500 lbs | 44 cu ft | Automotive parts |
| 48" x 40" x 40" | Double Wall (BC) | 3,500 lbs | 44 cu ft | Industrial components |
| 48" x 48" x 42" | Double Wall (BC) | 4,000 lbs | 56 cu ft | Large heavy items |
| 48" x 48" x 48" | Triple Wall (AAA) | 5,000 lbs | 64 cu ft | Maximum capacity |
| 40" x 48" x 48" | Triple Wall (AAA) | 4,500 lbs | 53 cu ft | Tall heavy items |
Octagon Sizes
Eight-sided containers for automated systems and specialized applications
| Diameter | Height | Weight Capacity | Volume | Application |
|---|---|---|---|---|
| 44" | 30" | 2,200 lbs | 27 cu ft | Compact operations |
| 46" | 34" | 2,500 lbs | 35 cu ft | Standard octagon |
| 46" | 38" | 2,800 lbs | 40 cu ft | Common height |
| 48" | 36" | 3,000 lbs | 42 cu ft | Popular choice |
| 48" | 42" | 3,200 lbs | 49 cu ft | Taller applications |
| 50" | 40" | 3,500 lbs | 51 cu ft | Maximum octagon |
Produce Bin Sizes
Specialized sizes for agricultural applications
| Dimensions | Type | Weight Capacity | Best For |
|---|---|---|---|
| 40" x 48" x 30" | Ventilated | 1,500 lbs | Apples, pears, citrus |
| 40" x 48" x 36" | Ventilated | 1,800 lbs | Root vegetables |
| 48" x 40" x 24" | Solid Wall | 2,000 lbs | Berries, delicate items |
| 48" x 48" x 36" | Wax Coated | 2,200 lbs | Wet produce |
Wall Construction Guide
Choose the right wall type for your weight and durability needs
Single Wall
$Light items, one-time use, cost-effective
Double Wall
$$Heavy items, reusable, better stacking
Triple Wall
$$$Very heavy items, maximum protection, most durable
Wall Type Selection Guide
Choose Single Wall When:
- • Contents weigh under 1,500 lbs
- • One-time or limited use
- • Lightweight materials (plastics, foam)
- • Cost is primary concern
Choose Double/Triple Wall When:
- • Contents weigh over 2,000 lbs
- • Multiple reuse cycles planned
- • Heavy items (metal parts, automotive)
- • Stacking 3+ boxes high
Volume & Capacity Reference
Cubic feet, metric conversions, and estimated product weight capacity
| Size (L×W×H) | Cubic Feet | Est. Light Fill* | Cubic Meters | Liters |
|---|---|---|---|---|
| 40x48x24" | 27 cu ft | 675-810 lbs | 0.76 m³ | 760 L |
| 40x48x30" | 33 cu ft | 825-990 lbs | 0.93 m³ | 934 L |
| 40x48x36" | 40 cu ft | 1,000-1,200 lbs | 1.13 m³ | 1132 L |
| 40x48x48" | 53 cu ft | 1,325-1,590 lbs | 1.5 m³ | 1500 L |
| 48x48x36" | 48 cu ft | 1,200-1,440 lbs | 1.36 m³ | 1359 L |
| 48x48x48" | 64 cu ft | 1,600-1,920 lbs | 1.81 m³ | 1812 L |
Pallet Compatibility Guide
Match your gaylord to the right pallet for optimal stability
| Pallet Type | Compatible Box Sizes | Notes |
|---|---|---|
| GMA Standard (48" x 40") | 48x40, 40x48 dimensions | Most common in North America, fits standard racking |
| Square (48" x 48") | 48x48 dimensions | Often used in food and beverage, good for rotation |
| Euro Pallet (47" x 40") | 44x44, custom sizes | European standard, some North American facilities |
| Half Pallet (24" x 40") | 32x40, smaller sizes | Retail displays, smaller operations |
| Custom Pallets | Any size | We can source boxes to fit your specific pallet |
Overhang Guidelines
- Box should not overhang pallet by more than 1"
- Slight underhang (box smaller than pallet) is acceptable
- Center box on pallet for balanced forklift handling
Stacking Recommendations
- Single wall: 2-3 boxes high maximum
- Double wall: 3-4 boxes high maximum
- Triple wall: Up to 5 boxes high
Size Recommendations by Industry
Expert suggestions based on industry-specific needs
Manufacturing
Balances volume with durability for parts storage
Agriculture
Airflow keeps produce fresh, moisture resistance
Recycling
Maximum volume for lightweight recyclables
Retail/Distribution
Fits standard racking, easy handling
Automotive
Heavy parts require maximum strength
Pharmaceuticals
Quality containers for sensitive products
Common Sizing Mistakes to Avoid
Learn from others' errors to make the right choice
Ordering by external dimensions
Products don't fit as expected, wasted space
Always specify internal dimensions for capacity planning
Ignoring weight capacity
Box failure, damaged products, safety hazards
Calculate total filled weight and add 20% safety margin
Wrong pallet match
Unstable stacking, wasted warehouse space
Verify pallet size first, then select matching box
Underestimating wall thickness needs
Boxes crush during stacking or transport
Use double wall for heavy items, triple for very heavy
Not planning for stacking
Limited warehouse height utilization
Consider total stacked height vs. ceiling/rack height
Need a Custom Size?
Don't see the size you need? We can source custom dimensions or modify existing boxes to meet your specific requirements. Common custom requests include:
Size Guide FAQs
Common questions about gaylord box sizing
What is the most common gaylord box size?
How do I calculate how many products will fit in a gaylord?
What's the difference between interior and exterior dimensions?
Can I get custom sizes?
How tall can I stack gaylord boxes?
What size box do I need for a specific weight?
Do octagon boxes fit on standard pallets?
What's the best size for shipping?
Quick Size Selection Tips
Consider Your Product
- Match box size to product dimensions with room for padding
- Calculate total weight when fully loaded
- Consider fill density (loose vs. packed)
- Plan for product settling during transport
Consider Your Space
- Match to pallet size for racking efficiency
- Check door and aisle clearances
- Consider stacking height limits
- Plan for truck loading (2x 48" = 96" trailer width)
Consider Your Operations
- Evaluate forklift capacity for loaded weight
- Plan for ergonomic access height
- Consider automation compatibility
- Plan for standard vs. custom ordering
Consider Your Budget
- Standard sizes cost less than custom
- Used boxes offer significant savings
- Bulk orders reduce per-unit cost
- Consider reusability for long-term savings
Still Not Sure What Size You Need?
Our team has decades of experience helping businesses find the right gaylord boxes. Tell us about your application and we'll recommend the perfect size.