Plastic Gaylords
When is a container considered a Gaylord?
Gaylord was originally a trade name for a bulk-size corrugated box.
Today, the term can refer to any pallet-sized container made of corrugated cardboard or a number of pallet-sized plastic or even metal containers. Sizes usual have a footprint of 48x40, 48x48 or 48x45. Sidewall heights usually vary from 24 to 50 inches.
You have probably seen a corrugated Gaylord box like this one in your local grocery or big box store attached to a pallet.
Low Cost Corrugated
First introduced in the 1930's, the corrugated Gaylord box was designed as a low cost way of moving bulk material. By the 1950's, these versatile containers were being used to move everything from plastic resin to watermelons.
The intentional choice of corrugated paper meant these boxes were never really expected to be reusable. Heck, even for commodities, the cost of the box was easily figured in with the product it contained. Even though there has always been a market for used Gaylords (recycled, if you will) the durability of paper is limited.
Longer Life Plastic
Making Gaylords more durable meant it could be used over and over, not only saving resources, but money too when figured over the life of the container. This prompted designers to think outside of the box (see what I did there?) and come up with corrugated materials made of plastic.
Plastic added exponential service life to the lowly Gaylord, making it suitable for closed loop programs. Check out a certain very large online fulfillment center and you will see hundreds of plastic corrugated Gaylords filled with everything from your underwear order to triple-caf sports drinks.
Next Level Durability
Taken to the next level of durability, the automotive industry championed the injection molded collapsible bulk container, a device meant to last for many "turns". At the same time, fixed-wall plastic containers began being deployed in fields to be filled with harvested produce. Again, these devices proved to be long lasting, reducing waste and lowering cost per trip.
To this day, no matter the industry, any one of these devices can still be referred to as a "Gaylord".
The Paper vs Plastic Sustainability Debate
There is a huge focus on sustainability these days, and the evolution of the Gaylord box is no exception. Consider this raging paper vs plastic debate:
Let's start with paper. Because traditional corrugated fiber gaylords are made from paper pulp, which is usually made from wood (can be recycled wood) the proponents of corrugated gaylord boxes claim maximum sustainability. And as a bonus, corrugated is an often recycled material.
Now we'll turn to plastic. Because plastic gaylord boxes last so much longer (in some cases hundreds of times longer) AND can still be recycled at the end of their useful service life, there is a strong case that the more durable product is also the more environmentally friendly.
Both sides make good points. What's your best option? Read on.
Do the Math
Wondering if you should choose a corrugated cardboard or plastic Gaylord box? There is no one answer, and for this author, I suggest always doing the math.
If you're ready to crunch the numbers, let's connect. Our experienced packaging pros can help you determine the best course. Not just for the operational and financial efficiencies you are looking for, but for the sustainability programs you are sure to be developing.
12/12/2024 by Hartson Poland on Containers