Pallet Size Cardboard Boxes: Standard Dimensions & Where to Buy

What Are Standard Pallet Size Cardboard Boxes?

Pallet-size cardboard boxes, often called Gaylord boxes in North America, are large corrugated containers specifically designed to fit standard shipping pallets. These heavy-duty packaging solutions enable the bulk transportation of goods while providing structural integrity throughout the logistics process. Unlike smaller shipping cartons, pallet boxes are engineered to contain substantial weight while maintaining their shape through multiple handling points in the supply chain.

The primary function of these specialised containers is to consolidate multiple smaller items into a single, manageable unit for efficient handling, storage, and transportation. By creating a unified load secured to a pallet, companies can dramatically reduce handling costs while improving inventory management. These containers typically feature reinforced corners and edges to withstand stacking pressure and the rigours of mechanical handling equipment.

The Difference Between Regular Boxes & Pallet Boxes

The distinction between standard shipping boxes and pallet-sized solutions extends far beyond simple dimensions. Regular cardboard boxes are typically designed for individual-package shipments via parcel carriers, with weight capacities rarely exceeding 30kg (70 pounds). These smaller containers prioritise ease of manual handling and are constructed with single-wall corrugation that provides adequate protection for limited weights.

Pallet boxes, in contrast, feature a significantly heavier construction with multiple corrugated layers, reinforced edges, and strategically placed structural supports. This robust design enables weight capacities ranging from 200 to 900+ kg (500 to 2000+ pounds), depending on the specific grade and construction. Additionally, pallet boxes are engineered with fork entry points for mechanical handling and often incorporate interlocking base designs that create stable connections with standard pallets.

Why Businesses Need Pallet-Specific Packaging

Implementing pallet-specific packaging solutions delivers multiple operational advantages that directly impact profitability. First, these specialised containers optimise cubic efficiency in transportation by maximising the usable space within trucks, containers, and warehouses. 

Beyond space utilisation, pallet boxes dramatically reduce handling costs by converting multiple small items into a single handling unit. This consolidation minimises the labour required for loading, unloading, and inventory management while reducing the risk of separated shipments. 

The structural integrity of purpose-built pallet boxes also provides superior product protection, decreasing damage rates and associated customer service issues. For businesses managing reverse logistics, standardised pallet boxes simplify returns processing and enable more efficient recycling or reuse of packaging materials.

European & International Pallet Box Sizes

Europa Pallet Boxes

Europa pallet boxes are designed to optimise European distribution and container shipping, serving as the foundation for logistics operations across the continent. At Globe Packaging, we offer these in two standard formats: the 1/2 Europa, measuring 770x570x660mm, and the full 1/1 Europa, measuring 1170x770x660mm. These dimensions are engineered for efficient space utilisation in European trucking and warehouse infrastructure, including doorways, elevators, and retail environments.

All Europa pallet boxes from Globe Packaging are manufactured from premium double-wall boards in a stitched format, featuring a rigid tray, cap, and sleeve construction for maximum strength and durability. This format creates a secure, stackable container ideal for pallet carrier distribution throughout Europe. 

Container Pallet Boxes

For UK and international shipping operations, Container pallet boxes have emerged as the preferred standard for maximising space utilisation in shipping containers. Globe Packaging offers the 1/2 Container, measuring 1070x870x550mm, and the whole 1/1 Container, measuring 1070x870x900mm. These dimensions are specifically engineered to optimise the interior space of standard shipping containers, making them ideal for ocean freight and large-scale distribution operations.

Container pallet boxes are widely used to fill containers, for distribution via pallet carriers, and for distribution to Amazon distribution centres. Like the Europa range, these boxes are manufactured from premium double-wall boards in a stitched format, comprising a rigid tray, cap, and sleeve, for maximum strength and durability. 

European Pallet Box Dimensions Table

North American Standard Pallet Box Dimensions

48" x 40" Pallet Boxes (GMA Standard)

The 48" x 40" footprint represents the dominant standard in North American logistics, accounting for approximately 30% of wooden pallets in circulation, making it the single most common size. Pallet boxes designed for these dimensions typically feature internal measurements slightly smaller (usually 45" x 37") to ensure secure placement on the pallet surface. 

This size has become the de facto standard because it optimises space utilisation in 53' trailers and 40' shipping containers while remaining manageable with standard forklifts and pallet jacks.

42" x 42" Pallet Boxes (Telecommunications Industry)

The telecommunications industry has widely adopted the square 42" x 42" pallet box format to accommodate specialised equipment and components. This configuration provides enhanced stability for tall, top-heavy loads while maintaining compatibility with standard handling equipment. The square footprint eliminates orientation concerns during loading and unloading operations, reducing handling time and potential errors.

Telecommunications pallet boxes typically feature reinforced sidewalls and additional corner protection to safeguard sensitive electronic components. These specialised containers often incorporate weather-resistant coatings or treatments to protect against moisture during transportation and outdoor storage.

48" x 48" Pallet Boxes (Chemical Industry)

For the chemical and industrial materials sectors, the 48" x 48" square pallet box format has emerged as a preferred standard. This larger footprint provides enhanced stability for dense, heavy loads while maximising cubic capacity for bulky materials. 

The square configuration prevents tip-overs during transport of high-centre-of-gravity loads such as drums, totes, and bulk raw materials. These specialised containers typically feature higher ECT ratings and reinforced bottoms to handle concentrated weight distributions.

While less common in general distribution networks, these oversized pallet containers remain standard in specific industrial applications where load stability and containment are paramount.

2 Best Places to Buy Pallet-Size Cardboard Boxes

1. Globe Packaging- Wide Selection and Fast Shipping

At Globe Packaging, we have established ourselves as an industry leader by offering one of the most extensive selections of pallet-sized cardboard boxes available online. Our inventory includes all standard Europa dimensions with multiple strength ratings and specialised features, including moisture resistance and reinforced bottoms. 

Beyond product availability, we provide comprehensive technical support that helps customers identify optimal specifications for specific applications. For companies seeking responsive service, expert guidance, and competitive pricing, we consistently rank among the top suppliers in the industry.

2. Amazon Business - Convenient Online Ordering

Amazon Business has revolutionised industrial packaging procurement by bringing the efficiency of its consumer marketplace to B2B transactions. Their platform offers hundreds of pallet box options with detailed specification information, transparent pricing, and the streamlined ordering process businesses have come to expect from the e-commerce leader. 

The integration with existing Amazon business accounts simplifies purchase approval workflows and expense management, particularly valuable for organisations with decentralised procurement functions.

Source Your Pallet Size Cardboard Boxes from Globe Packaging

Selecting the right pallet size cardboard boxes is essential for optimising your logistics operations, reducing shipping costs, and protecting valuable cargo throughout the supply chain. Whether you require Europa pallet boxes for European distribution or Container pallet boxes for UK and international shipping, understanding standard dimensions and strength ratings ensures your products arrive safely while maximising freight efficiency.

At Globe Packaging, we're one of the UK's leading packaging distributors, offering export-ready pallet boxes manufactured from premium double-wall boards in a stitched format for maximum strength and durability. Our range includes 1/2 Europa, 1/1 Europa, 1/2 Container, and 1/1 Container sizes-all available with or without heat-treated pallets for seamless export compliance. 

Whether you're filling containers, distributing via pallet carrier, or shipping to Amazon distribution centres, our rigid tray, cap, and sleeve format provides the protection your products demand. With next-day delivery across UK Mainland on orders over £50, same-day dispatch on orders placed by 4pm, and competitive pricing across all quantities, Globe Packaging delivers the quality and reliability logistics professionals need. 

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 *Note: Product listings, prices, and delivery times shown are approximate and subject to change. Contact Globe Packaging for the latest information.