Pallet box: bulk bins, gaylords and box pallets explained
A pallet box is a bulk container with a pallet-sized base that forklifts and pallet jacks can handle: a wooden bin, a corrugated gaylord on a pallet, a collapsible plastic bulk container or a steel box pallet. The EPAL box pallet has a 1200 × 800 mm inner base, is 970 mm tall and carries 1,500 kg.
"Pallet box" covers any container that combines a box with a pallet base. The right choice depends on whether the box is one-way or returnable, what it holds, and whether it must stack.
What is a pallet box?
A pallet box is a bulk container sized to a pallet footprint, handled as one unit by forklift or pallet jack. The base is either a separate pallet (a gaylord or collar sitting on a pallet) or built into the container (a box pallet or molded bulk container).
Types of pallet box
| Type | Material | Typical footprint | Returnable | Notes |
|---|---|---|---|---|
| Wooden pallet bin | Wood boards on a wooden pallet base | 48 × 40, 48 × 45 in, custom | Often | Agriculture, parts; can be built to any size |
| Gaylord box | Double or triple-wall corrugated, on a pallet | 48 × 40 in and others | Usually one-way | Bulk parts, resin, produce, recyclables |
| Collapsible plastic bulk container | Molded plastic with folding walls | Standard pallet footprints such as 48 × 40 in | Yes | Folds flat for return; access doors on some models |
| Steel mesh box pallet (stillage, cage) | Steel mesh walls on a steel base | 1200 × 800 mm (EPAL) and others | Yes | Automotive and European exchange |
| Pallet with collars | Hinged wooden frames on a standard pallet | 1200 × 800 mm and others | Yes | Adjustable height, folds flat |
How are they built?
EPAL box pallet
EPAL publishes these figures for its steel box pallet:
| Feature | Value | Imperial |
|---|---|---|
| Inside length × width | 1200 × 800 mm | 47.2 × 31.5 in |
| Height | 970 mm | 38.2 in |
| Volume | 0.75 m³ | 26.5 ft³ |
| Weight | about 70 kg (after 2011); about 85 kg for earlier units | about 154 lb; 187 lb |
| Safe working load | 1,500 kg | 3,307 lb |
| Maximum on the bottom box when stacked | 6,000 kg | 13,228 lb |
EPAL describes it as a steel lattice construction with four boards and two hinged panels, and it is widely used in automotive and European logistics.
Gaylords
A gaylord is a large corrugated box, typically double or triple wall, sitting on a separate pallet. One published 48 × 40 × 45 in triple-wall gaylord is rated 1,100 lb (499 kg). Board grade (ECT or burst), wall count, and whether the box has a full bottom or a flap bottom set capacity and stackability.
Wooden bins
Wooden bins are a wooden pallet with walls of boards or plywood nailed to posts. They are built to order in any size, which suits produce and parts that need a specific footprint. See produce.
Where are pallet boxes used?
- Automotive parts loops; see automotive
- Produce harvesting and storage
- Plastics and resin pellets
- Scrap, recyclables and bulk parts
- European logistics on the EPAL exchange system
Pros and limits
| Pros | Limits |
|---|---|
| Contains loose and irregular goods | Heavier and bulkier than a pallet alone |
| Stackable when rigid | Returnable types need return logistics |
| Collapsible types save return space | Corrugated loses strength when wet |
| Standard footprints fit racks and trucks | Steel and plastic types cost far more than a pallet |
Capacity and weight
Capacity depends on type. The EPAL box pallet is rated 1,500 kg (3,307 lb) with up to 6,000 kg (13,228 lb) on the bottom box in a stack. Corrugated gaylords are rated by their board grade, for example 1,100 lb (499 kg) for one triple-wall model. For wooden bins and custom containers, the builder rates the design. Stacking loaded boxes needs both the box walls and the base to be rated for the load above. See pallet load capacity.
ISPM 15
Steel, plastic and corrugated boxes are exempt from ISPM 15. Wooden bins, and wooden pallets under gaylords, need heat treatment and marking for export.
What drives the cost?
- Material: corrugated is cheapest; wood mid-range; plastic and steel highest
- Size and wall height
- Collapsible features, doors and lids
- Returnable life vs one-way use
- Quantity and freight (rigid boxes take up space when shipped empty)
Specifying a pallet box for a quote
- Type: wooden bin, gaylord, plastic bulk container, steel box pallet, collars
- Footprint, inside dimensions and height
- Contents, maximum weight, and density
- Stacking height when loaded
- One-way or returnable; collapsible
- Doors, lids, dividers, liners
- Food contact or cleanliness requirements
- ISPM 15 for wooden parts
- Quantity and delivery location
Related: pallet collar, steel pallet, plastic pallets. Pallet boxes are quoted as described items; use the other template to describe one and attach drawings or photos.
Frequently asked questions
What is a gaylord box?
A large corrugated box sized to sit on a pallet, often 48 × 40 in in footprint and made from double or triple-wall board. Gaylords hold bulk parts, resin pellets, produce and recyclables.
What is a box pallet?
A pallet with fixed or folding sides, usually steel mesh on a steel frame with a base that forklifts can enter. The EPAL box pallet is the most widely exchanged example in Europe.
What are the dimensions of the EPAL box pallet?
EPAL gives an inside length and width of 1200 × 800 mm, a height of 970 mm, a volume of 0.75 m³, a weight of about 70 kg for units built after 2011, and a safe working load of 1,500 kg.
Can pallet boxes be stacked?
Most rigid pallet boxes and box pallets are designed to stack when loaded. EPAL allows up to 6,000 kg on the bottom box pallet on a firm, level surface. Corrugated gaylords stack only if the board grade supports it.
Are pallet boxes ISPM 15 exempt?
Steel, plastic and corrugated boxes are exempt. Wooden bins and wooden parts on a box need treatment and marking for export.
Sources and references
Related
- TypesPallet collar: hinged wooden frames that turn a pallet into a boxA pallet collar is a frame of four boards joined by metal hinges that sits on a pallet to form an open box. Collars stack to build height and fold flat when empty. The common European collar fits a 1200 × 800 mm pallet, is 200 mm (7.9 in) tall and has 4 or 6 galvanized hinges.
- TypesSteel pallet: welded, galvanized and built for heavy loopsA steel pallet is fabricated from carbon or stainless steel sheet, channel and tube, usually welded and hot-dip galvanized or powder coated. It carries heavy loads, lasts for years outdoors and in hot processes, does not burn and is ISPM 15 exempt. Steel pallets weigh roughly 50–150 lb (23–68 kg).
- TypesPlastic pallets: types, materials, load ratings and how to buy themA plastic pallet is a molded or fabricated pallet made from HDPE or polypropylene. Types range from light nestable pallets (about 14–30 lb) to reinforced rackable pallets (about 35–70 lb). They are washable, ISPM 15 exempt and long-lived, cost several times more than wood, and carry three separate load ratings.
- TypesWooden pallets: types, construction, sizes and how to specify themA wooden pallet is a flat transport platform built from lumber deckboards fastened to stringers or blocks. In North America most are 48 × 40 in stringer pallets weighing about 30–70 lb (14–32 kg); in Europe the 1200 × 800 mm EPAL block pallet dominates. Wood must be ISPM 15 treated for most export.
- IndustriesPallets for fresh produceFresh produce ships mainly on 48 × 40 in pallets in North America, many of them pooled block pallets. Pallets must survive wet cooling, cold storage and long reefer hauls and let cold air flow through the load. Imported produce, including from Mexico, needs ISPM 15 treated and marked wood pallets.
- IndustriesPallets for the automotive industryAutomotive supply chains run on returnable plastic pallets, bulk containers and steel racks that cycle between suppliers and plants. OEM packaging guidelines set the footprints; 48 × 45 in is a common automotive size in North America. One-way wood pallets and ISPM 15 crates cover service parts and export.
- TypesEuro pallet (EUR / EPAL 1): dimensions, weight and constructionThe Euro pallet (EUR or EPAL 1) is a licensed European block pallet measuring 1200 × 800 × 144 mm (47.2 × 31.5 × 5.7 in). It weighs about 25 kg (55 lb), has 11 boards, 9 blocks and 78 nails, and carries a safe working load of 1,500 kg (3,307 lb). Only EPAL licensees may build and mark it.
More in Other materials
- TypesPresswood pallet: molded wood-fibre, nestable and ISPM 15 exemptA presswood pallet is a one-piece pallet molded from wood fibre and resin under heat and pressure. It has no nails, nests about 2.5:1 to 4:1, weighs roughly 25–35 lb (11–16 kg) in 48 × 40 class sizes and is ISPM 15 exempt as processed wood. It comes in fixed sizes and is not rackable.
- TypesMetal pallets: steel, stainless and aluminum comparedMetal pallets are fabricated from carbon steel, stainless steel or aluminum, usually welded. They carry heavy or hot loads, last for years in returnable loops, do not burn and are exempt from ISPM 15. Carbon steel is the strongest and cheapest metal, stainless and aluminum resist corrosion, and aluminum is the lightest.
- TypesAluminum pallet: light metal for food, pharma and cleanroomsAn aluminum pallet is a welded metal pallet, usually seal-welded so it can be washed and sanitised. It is lighter than steel, does not rust, is ISPM 15 exempt, and is used in food processing, pharmaceutical cleanrooms and hot or wet processes. It is among the most expensive pallet types.
- TypesPaper pallet: corrugated and honeycomb pallets explainedA paper pallet is made entirely from paper products: a corrugated or honeycomb paperboard deck on feet of paper tubes, honeycomb blocks or folded board. It is very light (from about 4 kg, 9 lb), recyclable and ISPM 15 exempt. Ratings reach about 750–1,000 kg, and humidity reduces strength.
- TypesSlip sheet: the thin pallet alternative, sizes, tabs and materialsA slip sheet is a thin sheet of solid fiberboard, corrugated board or plastic used under a unit load instead of a pallet. A push-pull lift truck attachment grips its tab and pulls the load onto its platens. Sheets for a 40 × 48 in load are commonly 43 × 51 or 44 × 52 in with 3–4 in tabs.
Last reviewed 2026-09-24. 835 words.