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The widest range of protective case options from an independent UK supplier.

Market leading ESD safe packaging for any static sensitive products and components.

Huge range of options and impartial advice on genuinely sustainable packaging for your business.

Pallet Optimised Boxes

Custom design

Tailored to your requirements

UK trade supplier

Huge product selection

Reduce costs

Range of strategies and services

Pallet optimised boxes

Reduce Transit / Storage Costs

Custom size corrugated boxes for maximum space efficiency

Pallet optimised boxes can significantly reduce costs. Rather than paying to ship empty space, or transporting pallets that are loaded inefficiently, custom sized corrugated boxes will maximise the efficiency of your shipping.

As well as being durable, easy to pack and featuring your branding, your boxes can also stack perfectly on the pallets you use with less than 50mm of space unused on the width / length – and no overhang either. Read More

Available Colours:

White cardboard material swatch
Brown Kraft cardboard material swatch
Cardboard with single colour print swatch
  • No obligation (and no pressure) quotes for any packaging
  • Free and impartial advice from UK based experts
  • Competitive pricing and full customisation options
FSC logo applied to Packaging manufactured by GWP (certificate FSC_C161914)

This product
can be
FSC® certified
on request


More information on Pallet Optimised Boxes

Is your business one of those paying hundreds or even thousands of pounds each year to ship empty space or excessive amounts of void fill?

Perhaps your goods frequently become damaged because of boxes overhanging the edge of your pallets? Or you transport many more pallets that you have too as there is no way to efficiently stack your boxes on them?

GWP can help with all of this, and more.

By analysing your products, current packing methods and the pallets you use, GWP can provide custom sized, pallet optimised boxes. Typically, these will leave less than 50mm of space on the length / width of your pallet and will not overhang either.

Manufactured from a durable corrugated cardboard – the exact grade of which is chosen based on your specific application – the precise stacking strength and transit protection levels required can also be calculated using advanced software. This can also often reveal that your existing corrugated boxes are actually over-spec’d, with material (and weight / cost) savings also being possible whilst maintaining performance.

What this means in practice is that not only can pallet optimised boxes significantly reduce your shipping costs, but you can also achieve this with no compromise on the protection offered to your products or parts when in transit.

Additional benefits of cardboard pallet boxes

There are of course a number of other benefits for using corrugated cardboard material for your pallet optimised boxes.

For example, as the corrugated boxes are collapsible it means they can be stored flat when not in use. Plus, once your product has been successfully delivered the boxes can be quickly collapsed and stored for the return journey (if applicable). The cardboard boxes can also be easily recycled and are fully biodegradable too.

There are also a number of enhancements you can choose for your pallet optimised boxes, such as printing of branding and instructions etc., as well as the use of protective coatings applied directly to the corrugated material.

Particularly suited for use with pallet boxes – and other forms of industrial packaging – are water resistance, anti-abrasion (useful for protecting the packaging of the items within the pallet box) and even VCI corrosion inhibitor. This prevents rusting or tarnishing of metal products or components.

The VCI inhibitor is essential for export, with products frequently exposed to atmospheric moisture during shipping by sea.

Plus, due to the way in which GWP is structured, if corrugated cardboard pallet boxes are not one hundred percent suited to your specific application, you can source plastic pallet boxes instead.

Perfect for particularly heavy-duty applications, these can be custom manufactured from Correx® corrugated plastic, or you can chose from a wide selection of moulded plastic stacking boxes.

Key Benefits of pallet optimised boxes at a glance

  • Maximises space efficiency when shipping pallets
  • Typically less than 50mm space not utilised on width / length
  • Corrugated boxes will not overhang pallet – minimising potential for damage
  • Material choice tailored to your product, stacking requirements and shipping method
  • Option for adding print / branding / instructions
  • Boxes can be coated to provide range of additional properties
  • Ultimately reduces your ongoing shipping costs
  • Can be sourced alongside inserts, dividers and full size pallet boxes


Pallet size data

Quarter Pallet (typical footprint): 600mm x 500mm or 600mm x 400mm

Half / Full Pallet (typical footprint): 1200mm x 1000mm

Please note – sizes can be tailored to specific pallet sizes as required


Questions about Pallet Optimised Boxes

Many businesses can overlook the benefits that properly optimising your boxes / pallets can provide. And those that do recognise this opportunity, are still likely to have a number of questions.

The below section looks to answer these commonly asked questions, but should you need further advice or assistance please get in touch.

How do you optimise boxes for pallets?

Pallet optimised boxes are effectively designed so that there is no – or very little – wasted space on your pallets (and the boxes will not overhang either). This involves a GWP design engineer analysing your products, your existing boxes, the protection requirements during transit and a number of other factors, to create a single or double wall box that provides optimum use of space.

Am I using the right pallets?

There may well be good reasons that you use a specific size of pallet. For example, your customers, may specify they have to be a certain type, or they work well with your existing warehouse etc. If you are flexible on the types of pallet you can use however, then GWP will be happy to recommend using different sized pallets if the analysis shows it could result in cost savings.

Will these boxes be able to stack to the required height?

Pallet boxes can be engineered so that they provide specific levels of stacking strength. Using advanced software and theoretical compression testing (which also calculates edge crush and burst strength parameters) it ensures your boxes can be stacked to the required height with no risk of damage.

Can I print my pallet boxes?

Any pallet boxes (or indeed any type of transit packaging) that you source from GWP can be enhanced with printing. Whilst it is nearly always a good idea to include your branding (free advertising!), you can also include other useful info such as part / model numbers, handling requirements, disposal instructions and so on.

Can I source full sized pallet boxes?

Besides individual, smaller boxes for placing on a pallet, you can also source full sized pallet boxes. These are a great choice for bulk shipping of items and can provide many of the same benefits as the pallet optimised boxes themselves.

Tailored Pricing / Specification

Source industrial packaging for your business

GWP Packaging has over twenty-five years of experience in designing and manufacturing industrial cardboard packaging.

An experienced and dedicated in-house design team will work closely with you to fully understand the challenges faced by your business, products and packaging, whilst an experienced support team will be happy to provide free advice and guidance in order to help identify the best solution to package your products.

You can also source much more than just pallet optimised boxes, including all of your corrugated packaging requirements, returnable plastic totes and containers, foam packaging and much more besides.

Sound good? Then ask for a free, no obligation quote today.

Custom Pallet Boxes

Options for enhancing your pallet optimised boxes

Although your pallet boxes will be tailored to provide specific levels of transit performance, there are optional ways in which you can improve performance still further. Please see below for the most popular of these.

Image coming soon

Custom Printed Pallet Boxes

Add branding, instructions and other info

Cardboard box dividers inside outer corrugated packaging

Cardboard Box Dividers

Improved use of space, plus transit protection

Foam packaging blocks

Foam Inserts / Dunnage

Enhanced levels of protection during transit

Cardboard packaging inserts coated with Anti abrasion coating

Anti Abrasion Coating

Protect items from surface scuffs / marking

Waterproof cardboard packaging

Liquiguard Water Proof Cardboard

Add resistance to moisture, oil and grease

Anti corrosion cardboard coating

VCI Corrosion Inhibitor

Protection for ferrous metal items against rust

Alternative Industrial Packaging

Similar industrial / transit packaging options available

Image coming soon

Pallet Boxes / Sleeves / Caps

Industrial packaging colours

Custom Sizes
Enquire for details

Single walled cardboard box

Single Wall Cardboard Boxes

Industrial packaging colours

Custom Sizes
Enquire for details

Double wall cardboard boxes

Double Wall Boxes / Cartons

Industrial packaging colours

Custom Sizes
Enquire for details

Triwall triple wall cardboard box

Triple Wall (Tri-wall) Boxes

Industrial packaging colours

Custom Sizes
Enquire for details

Correx dividers

Correx® Handling Items

Correx packaging colours

Custom Sizes
Enquire for details

A collection of composite packaging products (bags, crates, foam etc.)

View All Transit Packaging Options

Wide range of industrial packaging and handling options

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    John Elliott

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    Bill Chapman

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    As well as pallet optimised boxes, you can source a wide range of fully tailored transit packaging from GWP...