Boxes & cartons
Gaylords move the bulk, but the box world is bigger than one footprint. RSC cartons, telescoping two-piece boxes, sleeves, dividers — new or reclaimed, standard or custom, any run size.
Need cartons — new or reclaimed?
Send dimensions, style and quantity and we'll source or build them.
Not every job wants a pallet-sized bin. For shipping cartons, retail packaging and interior protection we stock and source the full corrugated range — RSC and specialty slotted cartons, telescoping two-piece boxes, sleeves, and dividers or partitions. Every style comes new or reclaimed, in stock sizes or custom runs, so you match the box to the product instead of forcing product into whatever is on the shelf.
A carton is a spec, not a shape
People say "box" and picture one thing. In reality a corrugated box is a stack of decisions: the style code that determines how the blank folds, the board grade that sets how many walls carry the load, the flute profile that trades cushioning against printability, and the inside dimensions measured to the product rather than the shelf. Get all four right and the box costs less, ships tighter and fails less often. Get any one wrong and you either pay for strength you never use or watch product arrive crushed.
That is the whole reason we carry the full range instead of a single stock size. A parts distributor kitting small components wants an open-top HSC bin in B-flute. A furniture brand shipping mirrors wants a five-panel folder that grips both ends. A meal-kit company wants an E-flute mailer that prints edge to edge and locks without tape. None of them wants the same box, and forcing one format on all three is how void fill and damage claims are born. Below we break down the styles, the board, the flutes and the sizing so you can spec with confidence — or hand us the product and let us spec it for you.
Common carton types
The styles below cover most needs. If yours is not here, describe it — odd formats are our comfort zone.
| Carton type | What it is | Best for |
|---|---|---|
| RSC (Regular Slotted Carton) | The workhorse. All flaps the same length, outer flaps meet in the middle. | Shipping, storage, e-commerce — 90% of general use |
| HSC (Half Slotted Carton) | RSC with no top flaps — an open-top tray or bin. | Parts bins, kitting, quick-access storage |
| FOL (Full Overlap Slotted) | Outer flaps fully overlap for a double-thick, tough top and bottom. | Heavy or shifting loads, rough handling |
| Five-panel folder (FPF) | One-piece wrap with a fifth panel that shields both ends. | Long, narrow product — rods, tubes, framed goods |
| Telescoping / two-piece | Separate lid and base that slide over each other. | Tall or awkward product, adjustable depth, display |
| Die-cut / mailer | One-piece folding carton, often self-locking, no tape. | Retail-ready, subscription and returns packaging |
| Sleeves | Wrap-around band or open-ended tube, no flaps. | Bundling, unit-load stabilizing, print branding |
| Dividers & partitions | Interlocking cells or pads that section the interior. | Glassware, bottles, fragile or multi-count packs |
| Layer pads / tier sheets | Flat corrugated sheets placed between stacked layers. | Palletized cans, jars, produce and canned goods |
How many walls do you actually need?
More walls mean more strength — and more cost and more fiber. We size the board to the load and the stack height, not to a spec sheet somebody copied years ago.
| Board grade | Construction | Typical strength | Best for |
|---|---|---|---|
| Single-wall | One fluted layer between two liners. | 32–44 ECT typical | General shipping, e-commerce, most cartons |
| Double-wall | Two fluted layers, three liners. | 48–61 ECT typical | Heavy, dense or stacked loads; most Gaylords |
| Triple-wall | Three fluted layers, four liners. | 67–90+ ECT typical | Bulk bins, industrial parts, near-crate strength |
ECT (Edge Crush Test) predicts stacking strength — the number that actually matters for palletized freight. Burst strength (Mullen) rates puncture resistance and still shows up on older specs. Tell us your load weight and stack height and we translate it into a grade.
The ripples that do the work
The fluting is the corrugated medium sandwiched between liners. Taller flutes cushion and stack; shorter flutes print smooth and die-cut clean. Combine them in double-wall for the best of both.
| Flute | Thickness | Density | Character |
|---|---|---|---|
| A-flute | ~5 mm | ~36 flutes/ft | Thickest. Best cushioning and stacking strength. |
| B-flute | ~3 mm | ~47 flutes/ft | Rigid flat-crush resistance; good for die-cuts and canned goods. |
| C-flute | ~4 mm | ~39 flutes/ft | The all-rounder — most shipping RSCs use it. |
| E-flute | ~1.5 mm | ~90 flutes/ft | Thin, smooth, prints well; retail and mailer boxes. |
| F-flute | ~0.8 mm | ~128 flutes/ft | Ultra-thin micro-flute for small retail and cosmetics packs. |
New or reclaimed — your call
The same honesty we bring to Gaylords applies here: we tell you when reclaimed will do the job for less.
Used & overstock cartons
Clean, once-used and surplus cartons pulled from the reuse loop. Ideal for internal transfers, storage, moving and any application where a brand-new box is overkill. Cheapest option and the lowest footprint by a mile.
First-run & custom cartons
Fresh board in exact sizes, strengths and print. The right pick for retail-ready packaging, tight tolerances, food contact or a consistent branded unbox experience.
Any dimension, any volume
One-piece die-cuts, unusual depths, extra-strong walls, printed sleeves — if you can spec it, we can run it. Small custom batches and full production quantities both welcome.
- Right-sized to your product to cut void fill and freight.
- ECT and wall tuned to the load, not over-built.
- Print, die-cut and self-locking options available.
Complete the load
Cartons rarely ship alone. Pair them with lids, liners, corner boards, banding and pallets from our accessories line to build a stable, protected unit load.
How to measure and spec a carton
Corrugated is always called out as inside dimensions — length × width × depth — because what matters is the space your product lives in. Here is the order we work through it.
Measure the product, not the old box
Take the largest length, width and height of what you are shipping, then add clearance for any liner, wrap or void fill. Measuring an old oversized box just carries the waste forward.
Add the right allowance
Snug reduces movement and freight; too snug bulges the walls and weakens the stack. We add a standard clearance per side and adjust for board thickness on double-wall.
Set the depth to the fill line
An over-deep box wastes fill and invites crush. Depth should end just above the product so the flaps close flat and the top load transfers cleanly to the corners.
Match board to load and stack
Heavier contents and taller pallet stacks call for higher ECT or an extra wall. Light, low-stacked goods do fine on economical single-wall — no reason to over-buy.
Run options & minimums
Reclaimed cartons ship in flexible quantities. New custom runs unlock exact sizes, print and construction — here is what a custom program can include.
Style & construction
RSC, FOL, HSC, five-panel folders, telescoping two-piece, die-cut mailers and self-locking trays — single, double or triple-wall to suit the load.
Print & finish
Flexo print, custom color, kraft or white liner, and interior tuning with dividers, partitions and pads for a retail-ready or protective fit.
Volume & MOQ
Small custom batches through full truckload production. Minimums scale with style and print complexity — plain stock sizes start low, custom die and plate work higher.
Send your annual volume and we will quote the most economical mix of stock, reclaimed and custom to hit it — often a blend beats going all-new or all-custom.
Industries that lean on our cartons
Different sectors, same demand — the right box at the right strength, without paying for board they will never use.
E-commerce & fulfillment
Right-sized RSCs and mailers that cut dim-weight freight and returns damage.
Food & beverage
Layer pads, tray-style HSCs and moisture-tolerant board for cans, jars and produce.
Manufacturing & parts
HSC bins, double-wall RSCs and custom dividers for components and kitting.
Retail & subscription
E and F-flute die-cut mailers that print sharp and unbox clean.
Furniture & fragile goods
Five-panel folders, telescoping boxes and partitioned packs for awkward, breakable product.
Movers & storage
Reclaimed RSCs by the bundle — cheap, sturdy and green for transfers and archives.
Boxes & cartons FAQs
What is the difference between an RSC and a Gaylord?
Do you sell dividers separately from boxes?
Is there a minimum order?
Can you match a carton I already use?
What flute and board grade should I choose?
Do you supply layer pads and tier sheets?
Are reclaimed cartons strong enough to trust?
Need cartons that actually fit?
Send the style, size and quantity — new or reclaimed, we'll sort it.