Technical · 5 min read

Choosing Liners for Bulk Boxes

Gauge, gusset, grade and antistatic: the four decisions behind a small part that prevents big failures.

At a glance

Quote request: Free, no obligation
Fulfilled by: Partner suppliers
Requests from: Across the US
Pricing: By written quote

Bulk containers filled with lined plastic components beside stacks of flattened board — Lined containers in service on a 48×40 footprint.

Gauge follows weight and edge

Two mil handles dry light goods. Three to four mil is the general-purpose range for powders, pellets and produce. Five to six mil belongs to anything with a sharp edge, anything heavy, and anything that will be dragged during discharge.

Gusseted or flat

A gusseted liner opens to the box's footprint and sits in the corners properly, which matters enormously for free-flowing product that would otherwise bridge. Flat liners are cheaper and acceptable for bagged or boxed contents inside the gaylord.

Food contact

If the liner will touch food, check current regulations and your customer's requirements before you order. Do not reason from appearance: clear film is not a credential. Ask the supplier for the resin documentation and keep it with your intake records.

Antistatic and barrier options

Resin pellets generate significant static during transfer; antistatic liners prevent both clumping and discharge hazards. Foil-barrier liners protect hygroscopic powders and extend shelf life for sensitive dry goods. Both should be specified at the same time as the box so they arrive matched.

Reference

The tables behind this guide

Construction limits and conversions: the working sheets that sit under the prose.

Construction, thickness and typical working capacity
Construction	Thickness	Typical max weight	Stacking	Typical use
Single wall C	5/32" (4.0 mm)	65 lb	Not for bulk	Lids, layer pads, dividers
Double wall BC	9/32" (7.1 mm)	900 – 1,200 lb	1 high loaded	General bulk under 1,200 lb
Double wall CC	5/16" (7.9 mm)	1,000 – 1,300 lb	1 high loaded	Slightly better cushioning than BC
Triple wall BCC	7/16" (11.1 mm)	2,200 – 2,500 lb	2 high loaded	The bulk workhorse
Triple wall ACC	1/2" (12.7 mm)	2,400 – 2,700 lb	2 high loaded	Dense product with cushioning need
Five wall AAC	5/8" (15.9 mm)	3,000 lb+	3 high, matched pallets	Castings, stampings, export

Height selection on a 48 × 40 footprint
Height	Cube	Fits	Best for	Watch for
28"	25.9 ft³	Low-clearance racking, pick faces	Dense product, ergonomic sorting	Doubles your container count on light goods
36"	33.3 ft³	Most standard racking	The default — best price and availability	Check reach height if hand-loaded
40"	37.0 ft³	Cooler racks, harvest lines	Produce, bakery, mixed DC	Top-edge wear climbs with reach
44"	40.7 ft³	Tall bays, textile sorting	Light bulky goods — foam, film, apparel	Hand-loading above 44" is uncomfortable
48"	44.4 ft³	Dedicated tall programs	Very light, very bulky loads	Triple wall only; never stack loaded

Quick conversions for bulk packaging
Measure	Imperial	Metric	Notes
Standard footprint	48 × 40 in	1,219 × 1,016 mm	The GMA pallet that standardised US distribution.
Triple wall thickness	7/16 in	11.1 mm	Takes about 7/8 in off interior width across both walls.
Typical capacity	2,200 lb	998 kg	Triple wall BCC, evenly distributed, matched pallet.
Container cube at 36"	33.3 ft³	0.943 m³	Outside dimensions, before board thickness.
OCC bale	1,000 – 1,400 lb	454 – 635 kg	Typical bale from a horizontal baler.
Trailer capacity, knocked down	400 – 600 units	—	53-foot dry van; cube limited, never weight limited.
Moisture ceiling for OCC	12%	12%	Above this you are selling water at a penalty.

FAQ

Common questions on this subject

Short answers to common questions. If yours is not covered, ask it on the form and a partner supplier in our network can answer it with your quote.

All 33 answers

Can I get pallets and liners too?

Yes. Recycled, export, plastic and presswood pallets, plus lids, caps, liners, corner boards, slip sheets and strapping, can be requested on the same form so they arrive with your boxes.

What exactly is a gaylord box?

A bulk corrugated container sized to a pallet footprint, usually 48×40 inches, built from two to five layers of corrugated board and handled by forklift. The name comes from the Gaylord Container Company; it is now a generic industry term.

Are used gaylord boxes strong enough?

For most applications, yes, provided they are graded properly. Corrugated loses much of its strength on its first compression cycle and much less on later trips. Ask the supplier to state wall count, flute and grade on the quote so you can check it against your load.

How much do used gaylords cost?

Pricing is set by the partner supplier who quotes your request. Grade, wall count, height, quantity and freight all move the number, and freight is usually the biggest variable, so ask for it as a separate line.

What is the minimum order?

It depends on the partner supplier. Used gaylords are usually sold by the banded bundle or the truckload. Put the quantity you need on the form and the supplier will tell you what they can do.

Can I sell my used boxes?

Often, yes. Send photographs and a count through the form. A partner supplier who buys used containers reviews them and, if the numbers work, makes an offer and arranges collection.

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One form and a free, no-obligation request. A partner supplier in our network follows up with grade, construction and freight.

Get a quote Resource hub

Choosing Liners for Bulk Boxes

Questions on this piece?

Gauge follows weight and edge

Gusseted or flat

Food contact

Antistatic and barrier options

The tables behind this guide

Common questions on this subject

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