New Gaylord Boxes — Only When You Really Need Them.
We'd rather sell you a used box. But when the spec doesn't bend — food contact, medical, first-use cleanrooms, regulated chemical packaging — we source new virgin-kraft boxes from a tight set of Midwest mills with documented chain-of-custody.
The five scenarios that justify a new box.
- Direct food contact. No prior-use boxes are FDA-defensible for unwrapped food, regardless of grade.
- Medical / pharma. Validated packaging chains often forbid reused outer corrugated.
- Cleanroom delivery. ISO 5–8 cleanroom protocols typically reject reused fiber dust.
- Regulated chemicals. DOT, UN, and OSHA packaging often require certified new construction.
- Aesthetic / retail. When the box is the package — branded triple-wall display.
Specs we can deliver.
| Spec | Detail |
|---|---|
| Material | 100% virgin kraft, FSC chain-of-custody available |
| Wall constructions | Single-wall (light), Double-wall (standard), Triple-wall (heavy-duty) |
| Edge crush test (ECT) | 32–82 ECT depending on wall & load |
| Mullen burst | 250–1100 lbs depending on construction |
| Food-grade liner option | FDA-compatible LDPE, PE, or aluminum-foil composite |
| 1–4 color flexo or unprinted | |
| Lead time | 3–7 business days typical, 10 days for custom die |
Where our new stock comes from.
We source new gaylord boxes from a tight set of four Midwest mills, three of which are FSC-certified and all of which provide documented chain-of-custody. We do not buy new-box inventory from overseas mills or from undisclosed brokers. If a customer's ESG framework requires named-mill sourcing, we can provide it.
Mill rotation across orders depends on three factors: customer spec, current mill capacity, and freight efficiency. Most orders ship from the closest qualified mill to the delivery location, which keeps embodied transport carbon down.
Specs we can quote, by construction.
| Construction | ECT | Mullen | Capacity | Lead time |
|---|---|---|---|---|
| Single wall, B-flute | 32 ECT | 200 lb | 700 lbs static | 3–5 business days |
| Double wall, BC-flute | 48 ECT | 350 lb | 1,500 lbs static | 3–5 business days |
| Double wall heavy, BC | 55 ECT | 500 lb | 1,800 lbs static | 4–6 business days |
| Triple wall, ABC | 65 ECT | 600 lb | 2,400 lbs static | 5–7 business days |
| Triple wall heavy, ABC | 82 ECT | 1,100 lb | 3,200 lbs static | 5–8 business days |
| Octagonal triple wall | 75 ECT | 750 lb | 3,000 lbs static | 7–10 business days |
| Custom die-cut | varies | varies | per spec | 10–14 business days |
The paperwork that comes with regulated orders.
FDA-grade LDPE or composite liner included; 21 CFR 177 documentation provided with order.
Cleanroom-defensible construction; chain-of-custody and certificate of compliance on every shipment.
Wipe-down cleanroom prep available; sealed shipping in poly-wrapped pallets with tamper-evident banding.
Boxes built to UN packaging standards (4G, 4GV) with certification stamp and per-shipment paperwork.
MIL-STD compliance available on triple-wall builds; serialization on request.
Boxes sourced from FSC-certified mills only; chain-of-custody documents attached to invoice.