Pallet Boxes

Cardboard pallet boxes for bulk, heavy and palletised goods

A pallet box is a large, heavy-duty corrugated cardboard container designed to fit a specific pallet footprint. It holds bulk or heavy goods as a single palletised unit, moved by forklift or pallet truck rather than handled box by box.

Packaging Express cardboard pallet boxes are made from strong double wall stitched corrugated cardboard in 300 K/T BC board, and are supplied with or without a heat-treated wooden pallet. They come in half and full sizes for Europa and standard container pallets, and are designed to maximise usable space in containers, haulage transport and warehouses.

The difference between a pallet box and a standard cardboard packaging boxes is scale and handling. A carton is sized for an individual parcel and lifted by hand. A pallet box is sized to the pallet beneath it and moved as a unit.

Pallet box specifications

What are cardboard pallet boxes used for?

Pallet boxes are used wherever goods are too heavy, too bulky or too numerous to send as individual parcels:

• Heavy and bulk goods consolidated into one handling unit
• Industrial components and manufactured parts moving between sites
• Warehouse storage, where a boxed pallet stacks more predictably than loose stock
• Export shipments, particularly where container space is at a premium
• Fulfilment centres, for bulk intake and transfer
• Large or awkward products that no standard carton will hold

Pallet box vs standard cardboard box

Half and full Europa pallet boxes

Europa sizes suit operations running Euro pallets, the common format across UK and European distribution. The half size at 770 x 570 x 660mm works for smaller consolidated loads, and the full size at 1170 x 770 x 660mm covers the whole Euro pallet.

Half and full container pallet boxes

Container sizes are built around the standard pallet footprint at 1075 x 870mm. The half-height option at 550mm is suitable for lower-profile loads, while the full-height option at 900mm provides greater capacity for bulky goods.

With or without a pallet?

With pallet. The box arrives with a heat-treated wooden pallet, ready to load and move. The straightforward option for export shipments and for anyone who does not hold spare pallets.

Without pallet. The box is supplied without a pallet, in packs of 15 rather than 8. This suits operations that already have suitable pallets in circulation.

What is a heat-treated pallet?

Heat treatment involves heating wooden packaging to a specified core temperature for a set period. It is used to reduce the risk of pests being transported in untreated timber.

Packaging Express supplies its pallets heat-treated as standard. Import requirements vary by destination, so check what the receiving country asks for before booking a shipment.

How to choose the right cardboard pallet box

Consider these six factors when choosing a pallet box.

• What are you packing? Heavy, bulky or loose goods can be consolidated into a single palletised load. Anything fragile still needs protective packaging inside the box.
• What are the dimensions? Measure length, width and height, allowing room for protection around the contents.
• Which pallet do you use? The pallet format you use, whether Euro or container, determines which sizes are suitable.
• Is it being exported? If so, the heat-treated pallet option keeps things simple.
• Do you already have pallets? If yes, the box-only option avoids paying for one you do not need.
• How will it be handled? Consider how the pallet box will be handled, transported and stored, including by forklift, pallet truck or warehouse racking.

How to pack a pallet box

• Choose a size that suits the load rather than the largest box available.
• Check the pallet and box are appropriate for the weight you are packing.
• Assemble the box on the pallet, using the caps, trays and sleeves supplied.
• Protect the goods inside with wrapping or packing peanuts where they could be damaged.
• Distribute weight evenly across the base, keeping heavier items low.
• Avoid large empty spaces, which let contents shift in transit.
• Close and seal the box, then secure the finished unit with stretch wrap or strapping.
• Check the load is stable before it is moved.

Cardboard pallet boxes vs wooden crates

Both hold bulk goods on a pallet, and each suits different situations.

Cardboard pallet boxes are lighter, which matters where freight is charged by weight. They arrive flat-packed, assemble without tools and are recyclable afterwards.

Wooden crates are more rigid and take more punishment over repeated long-haul journeys, which can suit very heavy, sharp or high-value machinery. They are heavier, bulkier to store and slower to build.

For many palletised bulk goods, a cardboard pallet box provides a lighter alternative to a wooden crate. For loads that need a rigid shell, a crate is the better fit.

Frequently asked questions

What is a pallet box?

A large, heavy-duty corrugated cardboard container designed to fit a specific pallet footprint, used to move and store bulk or heavy goods as one palletised unit. Packaging Express pallet boxes are double wall stitched corrugated cardboard in 300 K/T BC board.

What are cardboard pallet boxes used for?

Moving and storing heavy or bulk goods that are too large or numerous to send as parcels. Common uses include industrial components, manufactured parts, warehouse storage, export shipments and fulfilment centre intake.

What is the difference between a pallet box and a cardboard box?

Size and handling. A standard cardboard box holds an individual parcel and is lifted by hand. A pallet box is built to pallet dimensions, holds bulk goods and is moved by forklift or pallet truck.

What sizes do cardboard pallet boxes come in?

Four sizes across two formats. Europa sizes are 770 x 570 x 660mm and 1170 x 770 x 660mm. Container sizes are 1075 x 870 x 550mm and 1075 x 870 x 900mm. All are internal dimensions.

Can I buy pallet boxes in standard UK pallet sizes?

Yes. The container sizes are built around the 1075 x 870mm standard pallet footprint, in half height and full height. Euro pallet users are covered by the Europa sizes.

Are cardboard pallet boxes suitable for heavy items?

They are designed for heavy and bulk goods, using double wall stitched corrugated cardboard in 300 K/T BC board. Packaging Express does not publish a load limit, and capacity depends on the box size, the pallet, weight distribution and handling, so contact the team if you are packing to a specific weight.

Do pallet boxes come with a wooden pallet?

Both options are available. With a heat-treated wooden pallet, boxes come in packs of 8. As a box only, they come in packs of 15, which suits operations that already hold suitable pallets.

Can cardboard pallet boxes be used for export shipping?

Yes. They are sized to maximise usable container space, and the pallet option is supplied heat-treated, the standard treatment for wooden packaging in international shipping. Check the destination country's import requirements before shipping.

How do you secure a pallet box for transport?

Load and seal the box first, then secure it to the pallet. Wrapping pallets in stretch film holds the box and pallet together as one unit, and strapping adds further security for heavier loads. Check the load is stable before moving it.

Are cardboard pallet boxes recyclable?

The cardboard boxes are recyclable. Flatten them before recycling and check your local recycling service for kerbside collection requirements.

Buy cardboard pallet boxes online

We supply cardboard pallet boxes UK wide, in half and full Europa and container sizes, with or without a heat-treated pallet. Product codes, internal dimensions and pack quantities are listed above.

Still not sure which pallet box you need?

Tell us what you are packing, its dimensions and weight, which pallet format you use and whether the load is being exported. Our team can match the size and pallet option to the job.

Call the customer helpline on 0345 224 3691, request a call back, or use the Contact Us form.