How DTC operations actually use our boxes.
- Returns sortation. A grade-B doublewall gaylord per SKU, sitting in the returns processing area, holding incoming returns until they’re inspected and re-stocked.
- Inbound consolidation. Used to consolidate small inbound shipments from contract manufacturers into pallet-sized loads for outbound distribution.
- Closed-loop shipping. Our most ambitious DTC programs cycle the same dedicated gaylords between manufacturer, fulfillment center and outbound shipper for 8–12 trips per box.
- Replacement parts kitting. Smaller singlewall cases for parts and accessory kits that ship to retail or repair customers.
Why DTC brands like the closed-loop model.
The story is good — “our packaging gets reused six times before it ever gets recycled” is a marketing line that holds up under scrutiny. The economics are also better than people expect: closed-loop programs typically save 50–65% on packaging spend versus buying new.
Our reference case study.
Read about a six-month closed-loop pilot we ran with a Boulder outdoor brand in our blog post, “How we ran a closed-loop pilot with a Boulder outdoor brand”.
How to start.
Tell us your monthly outbound carton count, your average return rate and your willingness to standardize on a single gaylord footprint. Inside a week we’ll come back with a proposal — dedicated unit count, cycle time, replacement budget, and a quarterly impact reporting cadence.
Closed-loop math, in numbers.
The reason closed-loop programs work for DTC operations is that the same gaylord can take ten to fifteen trips before it retires, instead of one. If you are buying 200 new boxes per month at $28 each, that’s $5,600 monthly. A closed-loop program with 200 dedicated boxes cycling at twelve-day intervals replaces the entire monthly buy with a per-rotation fee that typically runs $2,200 to $2,800. Over a year that is $30,000 to $40,000 in packaging savings, plus a sustainability story that survives cynical scrutiny.
Specs we keep for DTC operations.
| Use case | Recommended footprint | Wall |
|---|---|---|
| Returns sortation | 40×48×40 | Doublewall |
| Inbound consolidation | 48×48×44 | Doublewall |
| Closed-loop shipping | 40×48×36 | Doublewall |
| Replacement parts kitting | 30×30×30 | Singlewall/Doublewall |
| Seasonal overflow | 40×48×40 | Doublewall |
Returns sortation, in detail.
Returns processing is the single most common DTC use case for our boxes. Here’s the typical setup: a returns processing area with one gaylord per SKU category, sitting in numbered positions on a long table or rack. Inbound returns are scanned, inspected, and dropped into the appropriate gaylord. When the gaylord fills up, it goes to the next station for refurbishment, restocking, or liquidation. Doublewall stock is the right choice here because the boxes get moved repeatedly between stations and need reasonable structural integrity through dozens of fill cycles.
Inbound consolidation, in detail.
Most DTC brands receive product from multiple contract manufacturers, often shipped in inconsistent carton sizes. Our customers use larger gaylords (typically 48"×48"×44" doublewall) to consolidate this mixed inbound into uniform pallet loads that fit cleanly on warehouse racks. The consolidation step reduces SKU proliferation in storage and makes outbound pick efficiency higher.
Why we like DTC accounts.
- The story is good — “real circular packaging” sells better than greenwashed claims.
- The volumes are predictable enough to schedule a recurring rotation.
- Returns rates create a natural balance of inbound and outbound box flow.
- Our customers in this space tend to be sustainability-minded by default.
- We get to brag about closed loops in our sustainability report.
DTC FAQ.
Will my customers see your boxes?
Almost never. Our gaylords are used inside the warehouse for consolidation and sortation. The boxes that go to your customers’ doors are typically printed mailers from a different supplier. We work in the back of the building.
Can the closed-loop boxes be branded with our logo?
We don’t custom-print reclaimed inventory because it destroys reusability across customers (see our blog post on why we don’t print). If branding is critical, we can apply a removable sticker instead, which we’ll happily do for closed-loop accounts.
What if our return rate is highly seasonal?
That’s actually a good fit for our seasonal flex program. We can scale your dedicated bin pool up for Q4 and back down for Q1 without forcing you to commit to peak-volume pricing year-round.
Can you handle a multi-warehouse rotation?
Yes — we run two-warehouse rotations for several DTC brands and a three-warehouse rotation for one outdoor company. The logistics are slightly more complex, but the same principle applies: dedicated boxes, fixed cycle, replacement buffer.