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New Gaylord Boxes When You Need Them
At Eco Boxes, our core mission is extending the life of used gaylord boxes and keeping packaging out of landfills. We believe that used boxes are the right choice for the vast majority of bulk packaging applications, and we will always recommend them first. However, we recognize that certain applications genuinely require new boxes — whether for regulatory compliance, food-grade certification, custom branding, or maximum structural performance. That is why we also offer a full line of brand-new gaylord boxes, manufactured to exact specifications and available in standard and custom configurations.
Our Recommendation
Before ordering new boxes, consider whether a Grade A used gaylord box might meet your requirements. Grade A boxes have been used only once or twice, show minimal wear, and cost 50-70% less than new boxes. For most internal warehousing, interplant shipping, recycling collection, and non-customer-facing applications, used boxes deliver the same performance at a fraction of the cost.
Our sales team will always give you an honest assessment of whether used boxes can meet your needs. We would rather save you money and the planet resources than upsell you to a new box you do not need. But when new is truly the right choice, we deliver the same quality, reliability, and competitive pricing that Eco Boxes customers expect.
Types of New Boxes Available
We carry the full range of gaylord box styles in new condition, from standard double-wall boxes to custom printed and custom sized configurations. Every new box comes with full manufacturer specifications and warranty.
Standard New Gaylord Box
Double Wall (BC Flute)Brand-new, never-used standard gaylord boxes with full manufacturer specifications. Clean, unprinted kraft or white exterior with crisp edges and maximum structural integrity. These boxes arrive flat-packed on pallets, ready to be erected and filled on your packing line.
Heavy Duty New Gaylord Box
Triple Wall (BC + E Flute)Triple-wall construction for maximum strength and stacking performance. New heavy duty gaylords deliver the highest burst strength ratings and edge crush resistance available in corrugated packaging. Essential for automotive, metal, and heavy industrial applications where failure is not an option.
Full Bottom New Gaylord Box
Double or Triple WallSealed bottom panel with no flap gaps, ensuring complete containment of granular materials, powders, small parts, and liquids. New full bottom gaylords are the required choice for food-grade, pharmaceutical, and clean-room applications where contamination control is critical.
Octagonal New Gaylord Box
Triple Wall (BC Flute)The eight-sided design delivers superior stacking strength and slightly more interior volume compared to rectangular boxes of the same footprint. New octagonal gaylords are the premium choice for warehouse operations that stack boxes three or four high.
Custom Printed Gaylord Box
Any Wall ConfigurationFull custom printing including your company logo, branding, handling instructions, barcodes, and regulatory markings. Custom printed gaylord boxes transform your outbound shipments into brand-building touchpoints. Single-color, two-color, and full-color flexographic printing available.
Custom Sized Gaylord Box
Any Wall ConfigurationNot every application fits a standard 48x40x36 box. Our manufacturing partners produce custom-sized gaylord boxes to your exact specifications. Whether you need a taller box for lightweight bulky items, a shorter box for heavy dense materials, or a non-standard footprint to match your pallet size, we can build it.
When to Choose New Over Used
We always encourage customers to consider used boxes first, but there are legitimate scenarios where new boxes are the right or required choice. Here are the most common situations where we recommend new.
Food-Grade and Pharmaceutical Applications
Regulatory requirements in the food and pharmaceutical industries often mandate that packaging materials be new, uncontaminated, and traceable to their manufacturing source. Used boxes cannot meet these requirements, regardless of their condition grade. New gaylord boxes with FDA-approved coatings and documented chain-of-custody are the only compliant option.
Customer-Facing Shipments
When your gaylord boxes will be seen by end customers, retailers, or business partners, a pristine appearance matters. New boxes with your company branding printed on the exterior create a professional impression that reinforces your brand identity. Used boxes, even in Grade A condition, may have minor cosmetic imperfections that do not align with premium brand standards.
Clean-Room and Controlled Environments
Manufacturing environments with strict particulate control requirements, such as semiconductor fabrication, medical device assembly, and precision optics, cannot risk the dust, fiber debris, and potential contaminants that used corrugated boxes can introduce. New boxes manufactured under controlled conditions are the only option for these environments.
Export and International Shipments
International shipments often face customs inspections and phytosanitary regulations that require new, clean packaging materials. Some countries have specific import regulations that prohibit or restrict the use of previously used packaging, particularly for agricultural and food products. New boxes with proper documentation ensure smooth customs clearance.
Maximum Weight and Stacking Requirements
When you are pushing the absolute limits of weight capacity and stacking compression, new boxes deliver their full manufacturer-rated performance. Used boxes, even in excellent condition, may have slightly reduced structural integrity from previous loading cycles. For critical loads at maximum capacity, new boxes provide the highest safety margin.
Long-Term Archival Storage
Documents, records, samples, and other materials that need to be stored for years or decades benefit from the maximum structural life that only a new box provides. Starting with a box at full strength ensures it will maintain its integrity throughout the entire storage duration without degradation, sagging, or collapse.
Custom Sizing & Options
When standard sizes do not fit your application, our manufacturing partners produce custom gaylord boxes to your exact specifications. From dimensions and wall construction to printing, coatings, and special treatments, every aspect of the box can be tailored to your requirements.
Custom Dimensions
Any length, width, and height combination you need. Our manufacturing partners can produce gaylord boxes from as small as 36x30x24 inches up to oversized containers exceeding 60x48x48 inches. Non-standard footprints are available to match specialty pallets, equipment dimensions, or storage constraints.
Wall Configuration
Choose the wall construction that matches your weight and stacking requirements. Single wall for lightweight applications, double wall for standard use, and triple wall for heavy-duty industrial needs. Hybrid constructions with different flute combinations are available for specialized performance requirements.
Printing and Branding
Transform your gaylord boxes into branded packaging with custom flexographic printing. Single-color printing is the most cost-effective option for logos and text. Two-color and full-color printing are available for more detailed graphics, product images, and complex branding elements.
Coatings and Treatments
Enhance the performance of your new gaylord boxes with specialized coatings and treatments. Water-resistant coatings protect against humidity and light moisture. Wax-impregnated options provide heavier moisture barriers for cold-storage and outdoor applications. Anti-static treatments are available for electronic component packaging.
Bulk Pricing Tiers
The more you order, the more you save. Our tiered pricing structure rewards volume commitments with progressively deeper discounts. All pricing includes standard specifications. Custom printing, coating, and non-standard sizes are quoted on a per-project basis.
Ideal for businesses testing new packaging configurations, one-time project needs, or small operations that do not require large inventories. Small orders are available for all new box types with standard lead times. No minimum quantity requirement for standard sizes.
The sweet spot for mid-size operations and regular users. Medium order quantities unlock meaningful per-unit price reductions of 10-20% compared to small orders. Custom printing becomes cost-effective at this volume, and we can accommodate recurring scheduled deliveries.
High-volume purchasing for established operations with consistent packaging needs. Large orders receive significant volume discounts of 20-35% off list pricing. Full custom sizing, printing, and coating options are available with dedicated account management and priority production scheduling.
For enterprise-level buyers with continuous, high-volume packaging requirements. Enterprise pricing is negotiated on a case-by-case basis and represents our deepest discounts, often 35-50% below list pricing. Includes dedicated account management, scheduled production runs, blanket purchase orders, and guaranteed capacity allocation.
All new box pricing is competitive with major corrugated manufacturers and distributors. Because we maintain strong relationships with multiple manufacturing partners across the country, we can often beat single-source quotes on both price and lead time. Contact us for a free quote — we guarantee a response within 24 hours.
Sustainability in New Box Production
Just because a box is new does not mean it cannot be sustainable. We work exclusively with manufacturing partners who prioritize environmental responsibility in their production processes. Our new boxes are made from a minimum of 35% recycled content, sourced from SFI-certified forests, and produced in facilities that operate on renewable energy wherever possible.
After your new boxes have completed their initial use, Eco Boxes will buy them back through our used box program, giving them a second, third, fourth, and fifth life before they are finally recycled into new corrugated material. Even when you buy new from us, you are participating in the circular economy.
Need New Gaylord Boxes?
Whether you need 10 standard new gaylords or 10,000 custom-printed containers, our team is ready to help. Get a free quote with competitive pricing, fast lead times, and flexible delivery options nationwide. We will also let you know if used boxes might work just as well for your application — saving you money and the planet resources.