Partial Flap Bottom 5-Wall Gaylord Boxes
A partial flap bottom 5-wall Gaylord uses shorter bottom flaps that meet but don't overlap, giving a single-layer base. Faster to assemble and 5-15% cheaper than full flap bottom — right for light-to-medium loads (under ~2,000 lb) on single-stack pallets.
Specifications
Box-body specifications match standard 5-wall construction. The partial flap bottom changes the base only.
| Bottom style | Partial flap — flaps meet, do not overlap (single-layer base) |
| Box construction | 5-wall corrugated, 3 kraft liners + 2 corrugated mediums |
| ECT rating | 32+ per TAPPI T 811 (same as full flap) |
| Practical load capacity | ~2,000 lb (lower than full flap due to single-layer base flex) |
| Stacking | Single-stack recommended; not designed for 2-3 high column loading |
| Pallet footprint | 48 × 40 in GMA |
| Heights available | 24, 28, 30, 36, 40, 42, 45, 48 in |
| Cost vs full flap | Typically 5-15% lower per box at equivalent quantity |
Partial flap vs full flap bottom
| Attribute | Partial flap (this page) | Full flap (FOL) |
|---|---|---|
| Base layers | Single | Doubled (overlap) |
| Practical load | Up to ~2,000 lb | Full 3,000 lb |
| Stacking | Single-stack | 2-3 high |
| Assembly time | Faster | Slower |
| Cost per box | 5-15% lower | Premium |
| Best for | Light-to-medium loads, one-way ship, high-throughput pack lines | Heavy or stacked loads, captive reuse loops |
Partial flap bottom FAQs
When should I choose partial flap bottom over full flap?
When loads are light-to-medium (under ~2,000 lb per box), boxes are single-stacked, and you want the 5-15% per-box cost savings. Common in distribution, cross-dock, recycling collection, and one-way shipping where the box won't be reused.
Can I stack partial flap bottom Gaylords two-high?
For very light loads, sometimes — but the doubled base of full flap bottom is what's actually designed for stacking. If two-high is your normal pattern, spec full flap and don't fight the trade-off.
How much does partial flap save versus full flap?
Typically 5-15% per box at equivalent quantity. At pallet-quantity orders the savings are meaningful; on a few boxes, less so.
Is the wall construction the same as full flap bottom?
Yes — both are 5-wall corrugated construction with the same ECT 32+ rating per TAPPI T 811. The only difference is the bottom flap geometry.
Why is the practical load capacity lower than full flap?
A single-layer base flexes under high column loads, which is the failure mode that limits practical capacity. Full flap (FOL) doubles the base layer and distributes the load across more material — that's why it can carry the full 3,000 lb rating.
Lead time for partial flap bottom Gaylord boxes?
Stock orders ship in 2-5 business days; custom prints or non-standard board grades add 2-3 weeks.
Can I get used partial flap bottom Gaylords?
Yes — many used boxes are partial flap construction. Specify "partial flap" in your quote so we filter inventory accordingly.
Are partial flap bottoms used in food-grade workflows?
Yes if the load is light and single-stack. Pair with an FDA-compliant PE liner per 21 CFR 177.1520. For heavy bulk ingredients near the weight cap, spec full flap instead.
Quote partial flap bottom
Tell us load weight and stacking pattern — we'll confirm partial flap is the right call.
Request a quote