Food-Grade 5-Wall Gaylord Boxes
A food-grade 5-wall Gaylord is a virgin-kraft corrugated box paired with an FDA-compliant polyethylene liner (21 CFR 177.1520, typically 3-6 mil) for direct contact with bulk food ingredients. The box is structural; the liner is the food-contact surface.
Specifications
Box specifications match standard 5-wall Gaylord construction. The food-grade configuration adds liner spec and handling-chain requirements.
| Construction | 5-wall corrugated, virgin kraft fiber (no recycled content) |
| ECT rating | 32+ per TAPPI T 811 |
| Burst test | ~600 psi per TAPPI T 810 |
| Static load rating | Up to 3,000 lb |
| Liner spec | FDA-compliant polyethylene per 21 CFR 177.1520 |
| Liner thickness range | 3 mil (dry powders) to 6 mil (wet / IQF frozen / oily) |
| Standard footprint | 48 × 40 in GMA pallet |
| Standard heights | 24, 28, 30, 36, 40, 42, 45, 48 in |
| Handling chain | Clean storage and fulfillment; no chemical or food allergen carryover |
Liner thickness by product type
The right PE liner depends on product moisture, density, and whether your product has any sharp or abrasive edges.
| Product type | Recommended liner | Examples |
|---|---|---|
| Dry powders | 3 mil PE | Flour, sugar, starch, protein powder |
| Mixed dry / granular | 4 mil PE | Dried beans, rice, nuts, dehydrated veg |
| IQF frozen | 5 mil PE | Frozen fruit, vegetables, individually quick-frozen proteins |
| Wet, oily, or sharp-edged | 6 mil PE | Brined product, pre-cooked meat, fats, sharp-edged frozen |
When in doubt, spec one mil heavier — the cost difference is small relative to a liner failure in transit or storage.
Food-grade Gaylord FAQs
Is the corrugated box itself food-safe, or do I need the PE liner?
The liner is what carries the FDA food-contact compliance (per 21 CFR 177.1520). The Gaylord box is the structural unit; the liner is the food-contact surface. Always pair the two for any direct bulk food contact.
What thickness PE liner do I need?
Rough rule: 3 mil for dry powders, 4 mil for granular dry product, 5 mil for IQF frozen, 6 mil for wet, oily, or sharp-edged product. When uncertain, go one mil heavier — the upcharge is small compared to a liner failure.
Do food-grade Gaylord boxes need to be new, or can I use refurbished?
For audit-grade food-contact workflows, always new. Used boxes have an inspection record but their cycle-age and prior contents can't be documented to a quality program. The liner is the contact surface, but the surrounding fiber and handling chain still need to be clean and traceable.
Are food-grade Gaylord boxes USDA-certified?
The PE liner carries the FDA food-contact compliance documentation (21 CFR 177.1520). The Gaylord itself is industrial packaging and does not carry a separate USDA certification because the liner is the contact surface. We can send the liner spec sheet for your auditor.
Can you supply PE liners with the box order?
Yes — combine boxes and liners on the same quote and we ship them together. Saves freight overhead and simplifies your dock staging.
What's the typical lead time for food-grade Gaylord boxes + liners?
Stock boxes ship in 2-5 business days; liner orders add 1-2 weeks if not in stock. Custom-spec liners (printed, gusseted, anti-static) run 2-3 weeks.
Can I use food-grade Gaylord boxes for organic-certified product?
Yes, with the right liner spec. Confirm your certifier's requirements for direct-contact packaging — most accept the standard 21 CFR 177.1520 PE liner. We can supply liner certs for your audit file.
What sizes are best for bulk food ingredients?
The 48 × 40 × 36 is the default for general bulk ingredients. Use shorter heights (28-30 in) for dense product like sugar, flour, or salt where you'd hit weight capacity before filling. Use taller heights (42-48 in) for low-density product like puffed grains or freeze-dried.
Can I get the box printed for food-grade applications?
Yes — flexo print uses food-safe inks on new orders. Confirm with your auditor that printing on the outer liner meets your quality program requirements; the inner liner that contacts the PE film is never printed.
Are food-grade Gaylord boxes recyclable?
The corrugated box is 100% OCC-grade kraft fiber and goes to paper mills as recycled-content feedstock. The PE liner is recyclable as plastic film (LDPE/HDPE) in regional film recovery programs.
Quote food-grade Gaylords
Send product type, quantity, and whether you need PE liners — we'll quote boxes and liners together.
Request a quote