When a new box actually makes sense.
- Direct food contact or pharma applications where contamination is regulated.
- High-end brand packaging where presentation is the product.
- Export crates that need a certified phytosanitary stamp.
- Specialty dimensions or flute profiles we don’t stock reclaimed.
- First-run prototypes before committing to a reuse program.
What we broker.
- Custom RSCs and HSCs, B/C/E flute, singlewall and doublewall.
- New gaylord boxes, triplewall and quadwall, 40×48 and 48×48 footprints.
- Die-cut packaging with up to 4-color flexo printing.
- Inserts, partitions and fit-to-product die cuts.
Our minimums and lead times.
For new custom cartons, expect 3–6 weeks lead time and minimum runs around 500–1,000 units depending on flute and print. For new gaylords, minimum is usually 48 units per footprint with 4–5 weeks lead time.
The catch.
We charge a small brokerage fee for new boxes and we’ll always quote you the used alternative alongside the new one. If the used option fits your spec we’ll tell you that in writing so you can make the call with the full picture.
The decision framework.
We get the “new or used” question on almost every first conversation. The decision usually comes down to four questions: (1) does the application require direct food contact or pharma-grade contamination control? (2) is the box going to be presented to a paying customer? (3) does it need a printed brand or regulatory mark? (4) does the application require an export phyto stamp? If the answer to any of those is yes, you probably need new. If the answer to all four is no, used is almost always the right call. We’ll help you walk through this on a quote-by-quote basis.
What our partner converters provide.
- Custom die-cut RSCs and HSCs in singlewall and doublewall.
- New gaylord stock in standard and custom footprints.
- FSC-certified fiber for ESG-conscious customers.
- 1-color, 2-color and 4-color flexographic printing.
- Inserts, partitions, and protective dunnage cut to fit.
- ISTA-certified packaging design for fragile or regulated products.
- Foodservice-grade and FDA-compliant stock.
What new boxes cost (and why).
A new doublewall 40"×48"×40" gaylord runs $24–$38 in our region depending on minimum order, lead time, print, and finish. The cost is dominated by raw material (kraft pulp pricing tracks the global commodity market), followed by mill labor, freight to the converter, converter setup, freight to you, and a margin for everybody involved. Reclaimed inventory bypasses most of those cost layers, which is why our reclaimed pricing is so much lower.
Lead times for new boxes.
| Order type | Standard lead time | Rush lead time |
|---|---|---|
| Stock new gaylords (no print) | 2–3 weeks | 1–2 weeks (premium) |
| Custom-printed RSCs (1-color) | 3–4 weeks | 2–3 weeks (premium) |
| Custom die-cut new boxes | 4–6 weeks | 3–4 weeks (premium) |
| FSC-certified custom stock | 5–8 weeks | 4–6 weeks (premium) |
New box FAQ.
Why don’t you stock new boxes?
Because every new box we stock represents capital tied up in inventory that we’d rather have circulating in our reuse pool. New is the exception, not the rule, so we broker it instead of stocking it.
Can I get a sample before I commit to a custom order?
Yes — most converters will run a small sample for prototyping, typically at a per-piece cost of $80–$200. We coordinate samples through the converter on your behalf.
Will you negotiate the converter’s price for me?
We’ll get you the best price we can within our partner network, but we don’t aggressively negotiate against our partners — they’re good to us and we’re good to them. If price is the main concern, used is the right answer most of the time.
What about FSC certification?
Several of our partner converters carry FSC chain-of-custody certification. We’ll match you with one if your spec requires it.