The short answer.
Empty corrugated containers flat-folded on pallets typically classify at freight class 200 or 250 in NMFC terms, because the density is terrible (roughly 3–5 lbs per cubic foot). This makes LTL expensive per unit.
Why density breaks the math.
LTL pricing is based on density — dense cargo is cheaper to ship. A pallet of paper reams at 25 lbs/cu ft rides at class 70. A pallet of flat-folded gaylords at 4 lbs/cu ft rides at class 200. Same weight, four times the freight cost.
How we work around it.
- We run full truckload (FTL) whenever possible. A 53-foot trailer loaded with folded gaylords hauls ~1,400 units and the per-unit freight comes out reasonable.
- We pair reverse-logistics pickups with outbound sales on the same route. Loaded both ways — the only way freight math works for empties.
- For partial loads we use dedicated milk runs: one truck picks up from five customers and delivers to five customers in one loop, sharing the freight cost across all ten legs.
- For single-pallet orders, we route through regional LTL partners but quote the freight separately so customers see exactly what the density penalty costs.
What this means for your quotes.
If you’re buying a single pallet across state lines, expect LTL freight to cost 40–80% of the box price. If you’re buying half a trailer or more, freight drops to 15–25% of the box price. The difference is density math, and it’s why small, distant orders are sometimes not economic — we’ll tell you when that’s the case.