We supply custom corrugated boxes from 6x6x6 up to 48x48x48 in ECT 32 and ECT 44 board, plus die-cut cartons, Gaylord bulk bins, and sheets, pads, and partitions. One- to three-color flexo printing is available on runs of 250 or more.
Manufacturers across North Alabama and the Southeast use us for boxes, sheets, pads, and Gaylords on the same truck as their pallets. Typical lead time is one to two weeks, and we can often accommodate urgent orders when capacity allows.
- ECT 32-44 Board grades
- 6x6x6-48x48x48 Carton size range
- Varies Run minimums
- 1-2 weeks Typical lead time
Custom Die-Cut Cartons Sized to Your Product
A box that is an inch too big costs you void fill, dimensional-weight freight, and crushed product. We die-cut cartons to your product's actual dimensions: RSC, full-overlap, one-piece folders, and custom styles with locking tabs or built-in cushioning panels.
Board grades run ECT 32 single-wall through ECT 44 and double-wall, with one- to three-color flexo print. Minimums vary by spec and manufacturer. Custom runs ship in 1-2 weeks from our Florence plant.
- RSC, FOL, one-piece folders
- ECT 32 through double-wall
- 1-3 color flexo print
Die-cut carton capabilities
| Attribute | Capability |
|---|---|
| Styles | RSC, FOL, one-piece folder, die-cut mailers, custom |
| Board | ECT 32, ECT 40, ECT 44, double-wall |
| Size range | 6x6x6 to 48x48x48 |
| 1-3 color flexo | |
| Minimum run | Varies by spec and manufacturer |
| Lead time | 1-2 weeks |
Gaylord Boxes & Bulk Bins, New and Used
Gaylords move bulk parts, regrind, produce, and scrap for a fraction of what returnable containers cost. We stock new and once-used Gaylord bulk bins on the standard 48x40 footprint in double- and triple-wall board, with or without lids and bottom flaps, rated for loads to 2,000 lb.
Used Gaylords run 40-60% below new and are inspected before they ship: dry, structurally sound, no contamination. Typical lead time is one to two weeks, sooner when the size you need is on hand.
- 48x40 footprint
- Up to 2,000 lb triple-wall
- New or inspected used
Gaylord bin options
| Attribute | Options |
|---|---|
| Footprint | 48x40 standard (custom sizes quoted) |
| Heights | 24 in to 48 in |
| Board | Double-wall or triple-wall |
| Load rating | Up to 2,000 lb (triple-wall) |
| Styles | Open top, lidded, full bottom flaps, drop-front |
| Condition | New or inspected once-used |
| Lead time | 1-2 weeks, subject to stock |
Corrugated Sheets, Layer Pads & Partitions Cut to Size
Layer pads stop pallet loads from crushing; partitions stop parts from scratching each other. We cut corrugated sheets and pads to any size up to 48x96 in single-, double-, and triple-wall board, and build chipboard or corrugated partition sets matched to your cell count and part depth.
Common uses across North Alabama: layer pads between rows of cans and jars, slip sheets under bagged product, tier sheets in machined-parts totes, and void panels in mixed cartons. Typical lead time is one to two weeks, and we can often accommodate urgent orders when capacity allows.
- Any size to 48x96
- Single through triple-wall
- Sold by the bundle
Sheet, pad, and partition capabilities
| Product | Spec |
|---|---|
| Sheets / layer pads | Any size to 48x96, ECT 32 to triple-wall |
| Standard pads | 48x40 and 44x36 stocked |
| Partitions | Corrugated or chipboard, custom cell count and depth |
| Edge options | Square cut or scored for wrap-around |
| Minimums | Vary by product and manufacturer |
| Lead time | 1-2 weeks |
Why Buy From Shoals Box & Pallet
ECT 32 to ECT 44 Board
Single-wall ECT 32 for cartons under 65 lb, ECT 44 and double-wall for heavy or stacked loads. We spec the board to your load, not the other way around.
Runs From 250, Not 5,000
Minimums vary by product, board grade, and print. You get plant-direct pricing without committing to a warehouse full of inventory.
Stock-and-Release Programs
We produce your annual quantity in one run for the best price, hold it in our Florence warehouse, and release it weekly as you need it.
Before Ordering
Frequently Asked Questions
What box strengths do you carry?
Standard grades are ECT 32 single-wall (loads to about 65 lb), ECT 44 single-wall, and double-wall board for stacked or heavy loads. We can spec bursting-test board (200#, 275#) on request.
What is the minimum order for custom boxes?
Corrugated carries production and manufacturer minimums that vary by product, board grade, and print. We will tell you the minimum for your spec when we quote it. There is no fixed minimum on pallets.
Do you sell Gaylord boxes?
Yes, both new and once-used Gaylords with 48x40 footprints in double- and triple-wall board, with or without lids and pallets. Used Gaylords run 40-60% below new.
How fast can I get boxes?
Typical lead time is one to two weeks depending on board grade, print, and tooling. Stock sizes move faster when they are on hand. Stock-and-release customers pull from inventory same day.
What is the minimum order for custom die-cut boxes?
Corrugated carries production and manufacturer minimums that vary by product, board grade, and print. We will tell you the minimum for your spec when we quote it. If it is more than you need, we can usually adapt a stock size with inserts or pads at a lower total cost.
How much does a cutting die cost?
Most steel-rule dies run $200-$600 one time, depending on carton size and complexity. We keep the die on file for reorders at no storage charge.
Which board grade should I use?
ECT 32 covers most cartons up to about 65 lb of contents. Go ECT 44 or double-wall for heavier products, stacked pallet loads, or long storage in humid conditions. Send the product weight and stack pattern, and we will help determine the right board specification.
Can you print our logo on the boxes?
Yes. One- to three-color flexographic print is standard on custom runs of 250+. Send vector art (PDF, AI, or EPS) and we will proof it before production.
How much weight can a Gaylord box hold?
Double-wall Gaylords handle roughly 1,200 lb; triple-wall handles up to 2,000 lb evenly distributed. Dense materials like regrind or metal scrap should always run triple-wall on a sound pallet.
What is the difference between new and used Gaylord pricing?
Used Gaylords typically run 40-60% below new. For internal moves and scrap, used is the obvious buy. For food-adjacent or customer-facing loads, buy new.
Can Gaylords be used for food products?
New Gaylords are used widely for produce and packaged food with a liner. Used Gaylords should not touch food-grade applications. We will tell you which stock qualifies when you order.
Do you buy back empty Gaylords?
We buy sound once-used Gaylords in truckload quantity. Call with a count and a photo and we will make an offer, or credit them against your next delivery.
What sizes of corrugated sheets can you cut?
Anything up to 48x96 in single-wall (ECT 32/44), double-wall, or triple-wall. Standard 48x40 and 44x36 layer pads are stocked for immediate shipment.
What is the difference between chipboard and corrugated partitions?
Chipboard partitions are thinner and cheaper, right for lightweight parts, glass, and cans. Corrugated partitions cushion better and stand up to heavier metal parts. We quote both when the application could go either way.
Can partitions be reused?
Corrugated partitions in a closed-loop tote program typically survive 5-10 round trips. If you run returnable totes, tell us. We will spec a heavier board that lasts longer per set.
Do you stock slip sheets?
We cut corrugated slip sheets to order in 3-5 days. For high-volume push-pull operations, ask about laminated kraft sheets. We will quote per thousand.
Quality Products. Priority Service. Delivered On Schedule.
Materials that hold up, a team member who answers, and deliveries that arrive when promised. Tell us what you're shipping, and we'll help determine the right packaging specifications.
Monday-Thursday 7:30-4:30 · Friday 7:30-12:00