Gaylord boxes are a well-known storage and transportation option in the shipping world — and they could be holding your business back.
Industries that deal with bulk materials often use Gaylord boxes for shipping throughout their supply chains. However, they have distinct drawbacks that leave many professionals hunting for an alternative.
If you want to reduce damage during shipping, keep workers safe and boost efficiency, the first step is finding a solution that’s more durable and cost-effective than the Gaylord box. Some options offer the same benefits and extra features that could transform your operations.
What Is a Gaylord Box?
A Gaylord box is a large, industrial-sized container for storing, transporting and shipping materials in bulk. They are made from either corrugated board, plastic or metal. Gaylord boxes vary in size and can be up to six feet tall. These boxes, named after the company that first developed them, are designed to fit on pallets for easy transportation and storage.
There are three primary types of Gaylord boxes:
- Rectangle (RECT): Regular rectangular boxes are suitable for various applications. They maintain their shape better than other varieties and are easier to fill, empty and store.
- Octagon (OCT): These boxes have eight sides and more corners than a regular Gaylord box, which makes them more robust.
- High-performance tote (HPT): Many Gaylord boxes have extras like corner posts, making them a durable option for bulk goods. They come in four and six-sided options.
Advantages of Using Gaylord Boxes
The primary purpose of any container is to prevent damage during shipping. Effective storage and transportation are even more important because just under 40% of consumers won’t order from a company again if they receive a damaged package.
Gaylord boxes are a common option for bulk shipping because they offer a few benefits for businesses. These boxes are good for bulk storage because they simplify storing and handling large quantities of materials. You can customize them with basic labelling and logos. These boxes can also generally withstand the vibration and jolting of transport.
Typical Challenges of Stacking and Storing Gaylord Boxes
Although it’s seemingly easy to ship Gaylord boxes, their design can pose issues with loading, unloading and storing. Your operation must always take stringent safety precautions.
Here are some of the common challenges of stacking and storing Gaylord boxes:
- Ergonomic risks: Gaylord boxes can be stacked, but manual lifting and over-the-top loading can pose an injury risk to employees, calling for lift assistance. SUREContainer® has removable side walls, which make controlled placement easier when loading and provide safer ergonomics.
- Handling and disposal: Gaylord boxes can be difficult to handle at the destination, and disposing of them can be complicated and costly. Boxes with a more lightweight design and recyclable materials are easier to handle and dispose of.
- Protection: Since Gaylord boxes have limited sizing options, some products require additional steps, such as using corner boards or edge protectors, to prevent crushing. Workers will also need to stack them carefully to distribute the weight evenly across the stack to prevent damage to lower boxes and maintain stability.
- Storage conditions: Gaylord boxes are susceptible to environmental factors. Store them in a temperature and humidity-controlled environment to extend their longevity. Avoid direct contact with the floor to prevent moisture from seeping in underneath. Damaged boxes can impact the integrity of the entire stack. Inspect boxes regularly for signs of moisture damage. If you see any issues, remove or replace the boxes immediately.
- Branding constraints: The blanks on Gaylord boxes are typically extensive, and the prints can cross scores that crack or distort. Ordering and getting custom printing can call for longer lead times, and you are also limited regarding spot colors and graphic design complexity. Custom boxes like SUREContainer can give your products a more professional appearance with a wider range of graphic capabilities.
- Limited size options: Gaylord boxes may come in one size or have limited sizes, which can waste cube space and rack up transportation costs. Custom options like SUREContainer can help you optimize your packaging according to your product requirements, reducing the need for wasted material and space.
A Better Alternative to Gaylord Boxes
Despite the potential benefits of Gaylord boxes, they also have significant drawbacks. Some require complex assembly, which can be labor-intensive and slow shipping. They also don’t allow the removal of side walls during the loading process. Instead, teams have to move items into bulk containers with stocking equipment.
Supply chain professionals are always looking for ways to boost quality and efficiency, and many packaging innovations have emerged in response to the limitations of Gaylord boxes.
SUREContainer® is at the forefront of innovation in this domain. It’s a new, ergonomic alternative to the traditional Gaylord container, offering teams a safe and efficient way to load contents. This cutting-edge design allows workers to remove one or more sides to place items in the container from the front instead of loading from overhead.
Some of the benefits of SUREContainer as an alternative to Gaylord boxes include:
- Controlled and efficient placement: As workers can load items from the front, they can place SUREContainer more efficiently and precisely to minimize the risk of damage.
- Cost-efficient and easy handling: SUREContainer can be built around a product and easily loaded with one or more side walls removed. Handling, shipping and disposal are easy for the receivers of the product, creating a positive experience across the supply chain.
- Improved packaging and storage: SUREContainer provides excellent stacking strength. It offers a transformable design and lightweight materials ideal for stacking cumbersome objects within a bulk container.
- Sustainable packaging option: The side panels of SUREContainer are solid fiber, honeycomb or corrugated and made from sustainable materials that reduce your environmental impact and appeal to consumers. They’re 100% recyclable and made from 80% post-consumer and 20% pre-consumer waste.
Choose Great Northern Laminations for High-Quality Shipping Solutions
When you partner with Laminations, you have access to a team of packaging experts who can engineer custom solutions for your unique projects. We’ve served the packaging industry for over 50 years with solutions that help you reduce assembly time by half while lowering shipping and material costs throughout the supply chain. As a premier supplier across industries, we have a wide range of quality products to transform your storage and shipping methods.
With SUREContainer, you can consistently deliver well-protected products that create a positive brand image, boost sales and streamline operations. Regardless of your industry or business size, we can make a design for the weight, shape and size of your goods.
Contact us to learn more about using SUREContainer for your business today!
