Skip to content
GAYLORD BOXES TXHOUSTON · SINCE 2009
Industry · Typical grade A / B

Plastics & Resin Processors

Regrind, purge, pellets and film — the biggest single user of bulk corrugated on the Gulf Coast.

48" × 40" × 30" or × 36"3-wall minimum, 4-wall for anything over 1,800 lbA for outbound sales, B for internal regrind
Spec summary: Typical size: 48" × 40" × 30" or × 36" · Wall count: 3-wall minimum, 4-wall for anything over 1,800 lb · Grade: A for outbound sales, B for internal regrind · Accessories: 4-mil anti-static liners, snap-on lids, corner boards.
Request a quote

Quote boxes for plastics & resin processors

Tell us what you have or what you need. A real person in Houston reads every one of these — usually within a couple of hours during dock time.

US or Canada, 10 digits — area code first.

US state or Canadian province.

ZIP like 77073, or Canadian M5V 2T6.

Whole boxes. A rough number is fine.

No phone number required from us — we quote in writing so you have the numbers on paper. We never sell or share your details.

Bulk bins stacked two high on pallets down a warehouse aisle, with banded knocked-down bundles alongside
Assembled bins stacked two high, knocked-down bundles alongside — the two ways stock waits to move.
Rows of octagon bulk bins on wooden pallets inside the Houston warehouse, some shrink-wrapped and stacked two high
Graded stock on the floor. Every one of these has been through the six-point inspection.

What this industry actually deals with

Houston sits on top of the largest petrochemical cluster in the western hemisphere, and almost every pound of resin that gets compounded, coloured, reground or purged along the ship channel spends part of its life in a gaylord box. Processors here burn through boxes faster than anyone: material is dense, the boxes get filled hot, and a single blown bottom on a forklift costs more in cleanup than a pallet of replacements.

The recurring problems

  • Hot purge and regrind soften a liner and shorten box life to a single trip
  • Dense pellets hit 2,000 lb long before the box is full
  • Static cling makes liners mandatory for virgin material
  • Inbound import boxes are metric-sized and do not sit right on GMA pallets

How we work with operations like yours

  • We buy your inbound import boxes back instead of letting them get baled
  • Standing weekly swap: full boxes out, graded empties in, one truck
  • Anti-static liners stocked in Houston so you are not waiting on a Midwest shipment
RECOMMENDED SPEC
Typical size
48" × 40" × 30" or × 36"
Wall count
3-wall minimum, 4-wall for anything over 1,800 lb
Grade
A for outbound sales, B for internal regrind
Accessories
4-mil anti-static liners, snap-on lids, corner boards
NOT SURE?

Run the Grade Decoder

Six questions about your load, storage and audience returns a wall count, grade and footprint — often a cheaper one than the industry default.

Stock guidance

Sizes and grades that suit plastics & resin processors

Matched from the recommended specification above. Every size links to a full spec page with load calculations and pallet fit.

Size (ID)VolumeCapacityWallsPer 53′ KDWhy it fits
48″ × 40″ × 3033.3 cu ft1,000 – 2,000 lb2-wall to 3-wall540Dense material — metal turnings, glass cullet, wet fiber, minerals.
GradeWhat it meansTrips leftPrice position
AOne fill, clean, no repairs, no cuts. The sweet spot.3–5 trips typicalRoughly 35–55% of new, depending on wall count and volume
BTwo or three uses. Up to two clean repairs. Structurally honest.2–3 trips typicalRoughly 20–35% of new
Before we quote

What we will ask you

Answer these in the message field and the first quote is usually the final one.

Weight of one full box

Weighed, not estimated. It sets the wall count, and estimates are where over-specification starts.

Stack height and dwell time

The bottom box carries everything above it, and corrugated creeps under sustained load.

Where it is stored

Climate controlled, dry warehouse, open dock or outdoors. A humid dock costs about 30% of your rating.

Who sees the box

Regulated, external customer, internal only, or one-way scrap. This decides grade, not strength.

How it is filled and emptied

Drop height, whether it is scooped, tipped or bottom-discharged. This decides liner and closure.

What goes out the other way

Empties, baled fiber or pallets. A paired trailer takes roughly 40% off each direction.

Questions

Plastics & Resin Processors — common questions

Which box size do most plastics & resin processors operations use?

48" × 40" × 30" or × 36" in 3-wall minimum, 4-wall for anything over 1,800 lb. That is a starting point rather than a rule — weigh a full box and run the Grade Decoder before committing to a trailer.

Can we buy used, or does this application need new?

Typical grade here is A / B. Used stock covers the large majority of the work; new is genuinely required only for direct food contact, regulated packaging, and shipments where the container represents your brand.

Do you buy our empties back?

Yes, and it is usually the cheapest arrangement available. A trailer delivering to you returns empty otherwise, so pairing an inbound delivery with an outbound buyback takes roughly 40% off each direction.

How fast can you deliver?

Same-day pickup from the yard on deep-stock sizes, next-day across most of the Houston metro, and two to four days on scheduled lanes to DFW, Austin, San Antonio and the Golden Triangle.

What is the minimum order?

One pallet for delivery — typically 20 to 40 boxes depending on wall height. No minimum at all for pickup from the yard on E Richey Rd.

Compare

Other industries

GRADE 1A / A

Food & Agriculture

Produce, nuts, grain, dry ingredients — where sanitation rules the spec.

GRADE B / C

Textiles & Apparel

Light, bulky, and priced by the cubic foot rather than the pound.

Ready to move some boxes?

Send the form once. We answer in writing with grades, quantities, sizes and freight — no phone tag, because we don't even have a phone number.

Quick reference

Every number on this site, on one screen

The numbers we get asked for most

Standard size
48" × 40" × 36"
Standard volume
40 cu ft nominal
Usable volume
80–85% of nominal
Capacity range
900 – 4,500 lb
Per 53′ trailer, KD
≈ 480 boxes
Per 53′ assembled
26 pallet positions
Overhang penalty
≈ 20% per inch
Humidity at 90% RH
≈ 50% strength
Trips per box
3–6 when handled well
New box CO₂e
≈ 13 lb
Reuse cycle CO₂e
≈ 1.2 lb
OCC per 53′ trailer
≈ 20 tons

Stocked sizes, capacities and truckload counts

Inside dimensionsVolumeCapacityPer 53′ KDStock
48″ × 40″ × 3640 cu ft1,200 – 2,800 lb480Deep stock
48″ × 40″ × 3033.3 cu ft1,000 – 2,000 lb540Deep stock
48″ × 40″ × 2426.7 cu ft900 – 1,800 lb600Regular stock
48″ × 40″ × 4246.7 cu ft1,800 – 3,000 lb420Regular stock
48″ × 40″ × 4853.3 cu ft2,500 – 4,000 lb360Regular stock
40″ × 48″ × 4550 cu ft2,400 – 3,400 lb390Seasonal
41″ × 28″ × 2516.6 cu ft700 – 1,400 lb900Regular stock
30″ × 30″ × 3015.6 cu ft500 – 900 lb1100Regular stock
45″ × 30″ × 4535.2 cu ft1,500 – 2,200 lb560Seasonal
47″ × 38″ × 4445.5 cu ft2,000 – 3,000 lb400Seasonal
48″ × 48″ × 4053.3 cu ft2,800 – 4,500 lb320Made to order
48″ × 40″ × 4044.4 cu ft2,500 – 4,000 lb400Regular stock

Inside dimensions. Outside runs ½″ to 1½″ larger per dimension depending on wall count — use OD for racking and trailer clearances. Full size chart →

Wall count and load ratings

WallsStatic loadStackTypical ECT
2-wall1,000–1,200 lb2 high48–61 lb/in
3-wall (tri-wall)1,800–2,000 lb2–3 high71–82 lb/in
4-wall2,500–3,000 lb3 high90–110 lb/in
5-wall4,000 lb+3–4 high120+ lb/in

Ratings assume dry, aligned, fully supported, short duration. Derating explained →

Grades, at a glance

GradeConditionTrips left
1AStraight from the corrugator, unused, printed or plain.4–6 trips typical
AOne fill, clean, no repairs, no cuts. The sweet spot.3–5 trips typical
BTwo or three uses. Up to two clean repairs. Structurally honest.2–3 trips typical
CWorking boxes. Cosmetically rough, structurally usable, cheap.1–2 trips typical
SCRAPEnd of life as a container. Beginning of life as fiber.Reborn as new liner within weeks

Every pass/fail threshold →

Derating factors — apply all that fit, multiplied

ConditionFactorWhy
Storage under a month×1.0No creep adjustment needed
One to six months loaded×1.4Corrugated creeps under sustained load
Over six months loaded×1.6Long-term storage
Dry warehouse×1.15Mild humidity exposure
Open dock, no A/C×1.3Most of Houston, most of the year
Outdoors or cooler×1.5Needs a lid as well

Required load = full box weight × (stack − 1) × creep × humidity. Run it automatically →

Service area and turnaround

AreaTurnaroundRegion
HoustonSame day, most ZIPsHarris County
Pasadena & Deer ParkSame dayShip Channel East
Conroe & The WoodlandsSame dayMontgomery County
Beaumont & Port ArthurNext day, scheduled routesGolden Triangle
Dallas–Fort WorthScheduled backhaul lanesNorth Texas
San Antonio & AustinScheduled lanes, 2–4 daysI-35 Corridor
Yard
1050 E Richey Rd, Houston, TX 77073
Monday – Friday
7:00 AM – 5:00 PM CT
Saturday
8:00 AM – 12:00 PM CT
Sunday
Closed
Telephone
None — every quote is issued in writing
Quote turnaround
One business day