Double Wall Boxes

What Is a Double Wall Box?

A double wall box is made from two layers of fluting and three liners, usually a B flute bonded to a C flute. The result is a board about twice as thick as single wall, with far more resistance to crushing and puncture. It is the board to choose when the contents are heavy, breakable or going to sit at the bottom of a stack.

When Is Double Wall Worth It?

Double wall costs more than single wall, so it should earn its place. These are the situations where we normally recommend it.

• Heavy contents such as books, metal fittings or machine parts
• Glass, ceramics and bottled liquids
• Boxes stacked several high in a warehouse or on a pallet
• Long journeys with several handling points
• Boxes that will be reused for storage or returns

If your parcel is light and travels on its own, single wall will usually do. The single and double wall guide sets out the trade-off.

How Much Stronger Is It?

In everyday terms, a double wall box keeps its shape under weight that would bow the sides of a single wall box, and its corners survive knocks better. We do not quote load figures because the real answer depends on size, stacking time, damp and how the load is spread. Tell us the contents and how boxes are handled and we will suggest the grade.

Which Styles Are Made in Double Wall?

Any of our corrugated styles. The regular slotted carton is the most common. Full overlap cartons add a further layer on the top and bottom for very heavy loads. Tuck front double wall boxes give a neat, tape-free opening for premium products that still need protection.

Can Double Wall Boxes Be Printed?

Yes. Because the board is thick and the surface has more texture, bold 1 and 2 colour designs print best: logos, handling marks and contact details. Full colour is possible, especially on a white outer liner, but fine detail softens slightly compared with thinner board.

How Should You Measure for Double Wall?

Exactly as for any box: send the inside size. The walls are thicker, so the outside of a double wall box is larger than a single wall box with the same inside dimensions. Allow for that if your boxes must fit a pallet footprint or a vehicle.

1. Measure the packed product.
2. Add space for padding around fragile items.
3. Send the inside length, width and height.
4. Tell us if there is an outside limit such as a pallet edge.

Packing Heavy Boxes Well

A strong box is only half the job. Fill gaps so contents cannot shift, put the heaviest items at the bottom, and tape the seams with an H pattern on the top and bottom. Keep heavy boxes to a size one person can lift safely, and add hand holes if they will be carried.