Custom Solutions
Tailored gaylord box solutions for businesses with unique requirements. Custom sizing, repair, consulting, and industry-specific programs.
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Custom Cutting & Sizing
Standard gaylord box dimensions do not work for every application. Our in-house fabrication team can cut, reshape, and modify gaylord boxes to match your exact specifications. Every modification is performed by trained technicians using industrial cutting and joining equipment.
Height Reduction
We cut standard-height gaylord boxes down to your specified height. This is the most common customization request and is ideal for businesses that ship products shorter than the standard 36-inch box height. Reducing height saves on shipping volume, reduces material waste, and makes boxes easier to access for manual packing operations.
Width and Length Adjustments
Need a box that does not fit the standard 48x40 pallet footprint? We can cut and reshape boxes to non-standard widths and lengths. While custom dimensions are subject to structural limitations, our team can advise on the optimal approach for your specific needs.
Hand Holes and Access Cutouts
We add hand holes, access doors, flap modifications, and ventilation cutouts to standard gaylord boxes. Hand holes make boxes easier to lift and maneuver without equipment. Access cutouts allow workers to reach contents without removing the box from a pallet or rack.
Partition and Divider Installation
We install corrugated partitions and dividers inside gaylord boxes to separate contents into compartments. This is essential for shipping fragile items, organizing different product SKUs within a single box, or preventing contents from shifting during transport.
Box Repair & Reconditioning
Why replace a box when you can repair it for a fraction of the cost? Our reconditioning team can extend the life of damaged gaylord boxes with professional repairs that restore structural integrity and functional performance. Reconditioned boxes cost 40 to 60 percent less than replacements.
Flap Replacement
Damaged or missing top and bottom flaps are the most common issue with used gaylord boxes. We cut and attach replacement flaps using the same corrugated material and construction method as the original. Repaired flaps provide full structural support and fold cleanly for proper closure.
Wall Panel Patching
Holes, tears, and punctures in box walls are repaired with matching corrugated patches applied with industrial adhesive. Our patches are cut to overlap the damaged area by a minimum of two inches on all sides, ensuring the repair is structurally sound and will hold up under load.
Corner Reinforcement
Corners are the most stressed area of any gaylord box, especially during stacking. We reinforce weak or damaged corners with corrugated angle supports bonded to both adjacent walls. This extends the stacking life of the box significantly and prevents cascading failures.
Bottom Rebuild
For boxes with compromised bottoms, we perform full bottom rebuilds by replacing the bottom panel entirely. This is particularly cost-effective for heavy duty and octagonal boxes where the walls are still in excellent condition but the bottom has failed from repeated heavy loads.
Waterproofing Treatment
We apply water-resistant coatings and moisture barriers to standard corrugated boxes for applications that involve outdoor storage, refrigerated environments, or moisture-prone contents. This treatment significantly extends the lifespan of the box in challenging conditions.
Printing and Label Removal
Previous printing, labels, and branding can be covered or removed to give used boxes a cleaner appearance. Options include label scraping, adhesive removal, and application of clean corrugated overlay panels that cover the entire exterior surface.
Packaging Consulting
Our packaging engineers bring decades of combined experience to help you optimize your bulk packaging strategy. From initial assessment to implementation, we provide actionable recommendations that reduce costs and improve performance.
Packaging Assessment
Our packaging engineers evaluate your current packaging setup and identify opportunities to reduce costs, improve efficiency, and minimize waste. We examine your products, shipping methods, storage conditions, and handling processes to recommend the optimal gaylord box configuration for your operation.
Box Specification Development
Not sure what type, grade, or size of gaylord box you need? Our team develops detailed packaging specifications based on your product weight, dimensions, fragility, shipping method, and storage environment. We take the guesswork out of box selection and ensure you get exactly the right container.
Cost Optimization Analysis
We analyze your current box spending and identify ways to reduce costs without compromising quality. Common savings come from switching grades where appropriate, optimizing box sizes to reduce void fill, consolidating orders for volume pricing, and implementing reuse programs.
Sustainability Planning
For companies with corporate sustainability goals, we develop packaging strategies that maximize reuse, minimize waste, and reduce carbon footprint. We provide detailed environmental impact reports that can be used in CSR reporting and sustainability disclosures.
Initial packaging consultations are complimentary for all prospective customers. Our team will visit your facility, assess your current setup, and deliver a written report with specific recommendations and cost projections.
Schedule a Free ConsultationPrograms for High-Volume Buyers
For businesses that use gaylord boxes regularly and in significant quantities, we offer structured programs that lock in pricing, guarantee availability, and simplify procurement. Choose the program that best fits your operational model.
Blanket Purchase Agreements
Lock in pricing and availability with a blanket PO that covers your estimated annual volume. You receive guaranteed pricing regardless of market fluctuations, priority access to inventory, and the flexibility to draw down quantities on your own schedule throughout the agreement period.
Vendor Managed Inventory
We monitor your box usage and automatically replenish your on-site inventory to agreed-upon par levels. You never run out of boxes, never over-order, and never need to manage purchase orders. Our team tracks consumption patterns and adjusts par levels seasonally.
Consignment Programs
We place boxes at your facility on consignment and you only pay for what you use. Unused boxes remain our property and can be rotated or returned at no cost. This program is ideal for operations with variable or unpredictable box consumption patterns.
Box Exchange Program
Trade your used boxes for credit toward new or reconditioned boxes. For every box you return to us, you receive a credit toward your next purchase. This creates a closed-loop system that reduces costs and waste simultaneously.
Industry-Specific Solutions
Different industries have different packaging challenges. We have developed specialized solutions for the industries we serve most frequently, combining our expertise in box selection, customization, and logistics into turnkey programs tailored to each sector.
Automotive Manufacturing
Custom-sized gaylord boxes designed for specific part geometries, with reinforced bottoms for heavy metal components. Partitioned interiors prevent damage to precision parts during interplant shipping. Anti-static treatments available for sensitive electronic components.
Food & Agriculture
Food-grade liners, ventilation cutouts for produce, and moisture-resistant coatings for cold storage environments. Our food-industry boxes meet FDA contact requirements when paired with appropriate liner materials. Custom heights for produce bins and harvest containers.
Plastics & Recycling
High-volume programs with recurring pickup and delivery for regrind, pellets, and scrap plastics. Custom-height boxes to optimize truck loading for lightweight but bulky materials. Color-coded labeling systems for material stream sorting.
E-Commerce & Fulfillment
Fast-setup auto-bottom boxes for high-speed packing lines. Custom-height boxes sized to reduce dimensional weight charges on parcel shipments. Returns consolidation containers with easy-access openings for processing centers.
Pharmaceuticals & Healthcare
Clean, Grade A boxes with documentation and traceability for pharmaceutical supply chains. Custom partitioned interiors for sensitive medical equipment. Temperature-indicator compatible packaging for cold-chain logistics.
Electronics & Technology
Anti-static treated boxes for sensitive electronic components. Custom foam-insert installations for high-value equipment. Reinforced packaging for heavy server equipment and industrial electronics with integrated cushioning systems.
Need Something Custom?
If you do not see exactly what you need on this page, reach out anyway. Our custom solutions team thrives on unique challenges. We have built custom packaging programs for hundreds of businesses and chances are we have solved a problem similar to yours before.