5-Wall Gaylord box sizes
Every 48 × 40 in Gaylord Box Size We Stock
Standard pallet footprint, eight different heights. Match the height to your product's density and your racking — the rest of the spec stays the same.
Why we offer eight sizes on one footprint
The 48 × 40 in pallet base is the de facto US shipping standard (the GMA pallet). Keeping every Gaylord on that footprint means warehouses, racking, forklifts, and trailers all handle the box identically — the only spec that changes between sizes is height. That makes the "which size?" decision a single question: how much vertical space do you need?
The answer comes from your product's density. A 5-wall Gaylord holds up to 3,000 lb regardless of height — so if your product weighs more than about 110 lb/ft³, the tallest box would never fill before hitting the weight cap, wasting freight cube. Conversely, if your product weighs under 30 lb/ft³, the shortest box would fill before reaching meaningful weight, costing you trailer slots.
The eight standard heights — 24, 28, 30, 36, 40, 42, 45, and 48 inches — give you enough granularity to land on a size where weight and volume run out at the same time. That's the efficient spot. The 48 × 40 × 36 is the most-ordered because it covers the middle of the density curve; the 48 × 40 × 45 is the second most-ordered because it's the largest height that still fits cleanly into typical recycling and bulk material freight.
The eight standard heights
Quick density chooser
If you know your product's bulk density, this maps it to the most efficient starting size:
| Product density | Recommended height | Typical example |
|---|---|---|
| Very heavy (90+ lb/ft³) | 48 × 40 × 24 | Foundry sand, metal turnings, glass cullet |
| Heavy (60-90 lb/ft³) | 28 / 30 in | Auto parts, castings, dense plastics |
| Medium (40-60 lb/ft³) | 48 × 40 × 36 | General manufacturing, mixed bulk goods |
| Light (20-40 lb/ft³) | 40 / 42 / 45 in | Plastic regrind, fiber, foam, textile scrap |
| Very light (under 20 lb/ft³) | 48 × 40 × 48 | EPS foam, shredded fiber, bulk insulation |
Not sure which size?
The simplest default: pick 48 × 40 × 36. It's the most-ordered size for a reason — 40 cubic feet on a standard pallet covers the middle of nearly every industrial density curve, fits most racking, and works with every trailer load plan. Re-spec to a shorter or taller height once you have a real-load weight history. Send your product and weight along with a quote request and we'll spec it.