Step 1
Triage at the grading bench
A box fails as a container — crushed vertical edge, one delaminated panel, a cut discharge port. The grader checks how many panels are sound, dry and undamaged.
Products · second life
What a retired gaylord becomes next.
A box that can no longer hold two thousand pounds still contains forty square feet of perfectly sound five-wall board. Our cutting table turns that into the parts other people buy new — and it is the most satisfying thing that happens in this building.
- Minimum run
- 50 pieces
- Tooling charge
- None for simple profiles
- Source
- Rejected panels only
Send a drawing or a sample
Dimensions, quantity and what the part has to survive. Put the part name in Product Type and we will quote from the reject stream.
Answer first
One rung above recycling, at half the price of new.
When a box fails grading, the industry default is a baler. But a five-wall gaylord side panel is 1,300 psi board in perfect condition — the same material a converting plant would sell you as new pad stock at four or five times the price. Cutting rather than pulping keeps the fibre in its highest-value form, consumes no water and no heat, and costs the customer less.
About six per cent of everything that arrives here leaves as a fabricated part instead of a bale. We would like that number to be higher, which is why we actively buy damaged panels from customers who would otherwise scrap them.
Somebody sent us eleven cut-open octabins expecting scrap value. They went out as three thousand corner pads for an appliance shipper down the road.
Catalogue
What comes off the table.
Layer pads & sheets
Flat pads cut to any rectangle up to 60 inches, in single through five-wall. The workhorse: pallet top sheets, layer separation, slip sheets.
From $0.34 each
Dividers & partitions
Slotted cell dividers and H-partitions assembled from reclaimed board. Cell counts to your drawing.
From $0.95 each
Trays & shallow boxes
Open trays cut and folded from sound panels — parts handling, WIP movement, kitting and picking.
From $1.20 each
Corner & edge protection
Cut corner pieces and edge runners for banding protection, an alternative to buying virgin corner board.
From $0.28 each
Display bases & plinths
Rigid stacked-panel bases for exhibitions, retail displays and photography sets. Surprisingly load-bearing.
Quoted per project
Prototype furniture
Stools, shelving units and counters built from laminated panels — used for events, pop-ups and student projects.
Quoted per project
Specs
What the table can and cannot do.
| Capability | Range | Tolerance | Notes |
|---|---|---|---|
| Maximum cut size | 60 × 96 in | ± 1/16 in | Larger parts made as multi-panel assemblies |
| Board thickness | Single wall to 5-wall | — | Flute orientation chosen for the load direction |
| Straight cuts and slots | Any profile | ± 1/16 in | No tooling charge |
| Scoring and folding | Up to 5-wall | ± 1/8 in | Triple and five-wall need wider score allowance |
| Die-cut curves | Simple profiles | ± 1/8 in | Complex dies quoted separately |
| Lamination | 2 – 6 panels | — | For display bases, plinths and furniture |
| Minimum run | 50 pieces | — | No maximum; long runs scheduled around box grading |
Questions
Upcycled goods, answered.
What is the difference between upcycled and recycled here?
Recycled means the board goes back to a mill, gets pulped and becomes new board. Upcycled means we keep the board in its existing, finished form and cut it into a useful part - no pulping, no water, no heat. It sits one full rung higher on the waste hierarchy and it is dramatically cheaper for the customer.
How strong are parts cut from used board?
As strong as the panel they came from, which for five-wall gaylord sides is considerably stronger than most new die-cut pad stock. We cut only from panels that pass the same moisture and crush checks as our sellable boxes, and we orient the flute for the load direction the part will see.
What is the minimum run?
Fifty pieces. There is no tooling charge for straight cuts, slots and simple die profiles - we cut to a drawing or to a physical sample you send us.
Can you make display or furniture pieces?
We make display bases, plinths, riser blocks and prototype furniture for exhibition and retail use. We are a cutting table, not a design studio, so bring a drawing or a reference and we will tell you honestly whether corrugated is the right material for it.
How a part is made
From rejected box to finished piece, in six steps.
Nothing here is complicated. It is simply a route that almost nobody in the trade bothers to build, because baling is faster.
Step 2
Panel recovery
Sound panels are cut free of the damaged structure and stacked by construction and board weight. Damp or delaminated panels go to the baler instead.
Step 3
Board matching
We find the reclaimed construction that meets your strength requirement and tell you exactly what it is — we do not substitute quietly.
Step 4
Flute orientation
Decided against the load direction the part will see. Get this wrong and a pad that should support weight folds under it. It is the mistake first articles exist to catch.
Step 5
Cut and score
Up to 60 × 96 inches, tolerance one sixteenth on straight cuts and one eighth on scores and simple dies. No tooling charge on straight profiles.
Step 6
Band, count, ship
Banded in counts you specify, shipped on our own trucks or added to your next box order on a single freight bill.
What it replaces
Every part here has a virgin equivalent, and a price gap.
The environmental argument is real, but customers buy these because they cost forty to sixty per cent less than the new die-cut stock they are replacing.
| Part | Ours | New equivalent | Saving |
|---|---|---|---|
| Layer pad, 18 × 24 in | $0.44 | $0.95 – $1.20 | 54 – 63% |
| Pallet top sheet, 48 × 40 | $0.62 | $1.40 – $1.85 | 56 – 66% |
| Slotted divider, 6 cell | $0.95 | $2.10 – $2.60 | 55 – 63% |
| H-partition | $1.35 | $2.80 – $3.40 | 52 – 60% |
| Open tray, cut and scored | $1.20 | $2.60 – $3.60 | 54 – 67% |
| Corner piece | $0.28 | $0.60 – $0.80 | 53 – 65% |
| Edge runner | $0.22 | $0.48 – $0.62 | 54 – 65% |
| Display base, laminated | Quoted | Timber or foam board | 40 – 55% |
Honest limits
What we will not pretend to be.
We are a cutting table in a box yard, not a converting plant or a design studio. The distinction saves everybody time.
We are genuinely good at
- Straight cuts, slots and simple die profiles from 50 pieces
- Matching a reclaimed construction to a strength requirement
- Flute orientation for a stated load direction
- Short runs and repeat runs scheduled around grading days
- Toll cutting from board you send us
- Telling you when a part should be bought new instead
We are not the right supplier for
- Certified food-contact parts — traceability we cannot provide
- Printed or brand-facing pieces
- Complex tooled dies at high volume
- Guaranteed mill certification on the board
- Tolerances tighter than one sixteenth of an inch
- Design work — bring a drawing or a sample
Before you scrap damaged board, send us a photograph.
We buy panels other people bale, and we will quote you the parts they could become instead.