double wall boxes

double wall boxes are corrugated cardboard boxes built with two layers of fluted board between three outer liners, giving them much greater stacking strength and crush resistance than single wall cartons. UK warehouses, manufacturers and online sellers choose double wall boxes for heavy, fragile or valuable goods, and for any parcel that will be stacked, stored or handled several times before it arrives.

How double wall boxes are constructed

Corrugated board is made by bonding wavy fluted paper between flat liner papers. A single wall board has one fluted layer, while a double wall board has two fluted layers with a liner between them and a liner on each face, making five layers in total. Those extra layers resist bending and puncturing, and they spread the pressure from boxes stacked above, which is the main cause of crushed parcels in vans and warehouses. Our double wall shipping boxes use this construction for demanding loads.

Flute combinations and what they change

Different flute sizes can be combined in one double wall board. Larger flutes give more cushioning and vertical strength, while smaller flutes add stiffness and a smoother surface. Combining two flute types balances both qualities, which is why double wall board performs well for mixed loads such as glassware, ceramics, electrical goods and vehicle parts. Board grade matters as much as size, so the contents and their weight should always guide the specification.

When single wall is not strong enough

Single wall cartons suit light and robust products, and our single wall corrugated boxes cover those everyday needs well. Step up to double wall when the contents are heavy for the size of the box, when the product would be costly to replace, when parcels are stacked on pallets, or when the journey involves several handling stages. If a single wall box bulges or its corners soften during a trial pack, the load needs the stronger board.

Uses for double wall boxes in shipping and storage

Businesses use double wall boxes for machinery parts, tools, bottled goods, books in quantity, household appliances and export orders, and removal and storage firms rely on them because they survive repeated use. They also suit warehouse storage, where boxes may sit stacked for months without the base layer sagging. For the heaviest work, compare our heavy duty shipping boxes alongside standard corrugated shipping boxes to match the board to the load rather than paying for strength you do not need.

Packing double wall boxes so they perform

Strong board works best with sensible packing. Place the heaviest items at the base, fill gaps so nothing can move, and keep weight shared evenly rather than concentrated in one corner. Seal the base and top with strong tape along the centre seam and the edges, and add strapping for very heavy loads. Custom Postal Boxes manufactures in Wolverhampton with low minimum order quantities, free design support and free UK delivery, and printing can add handling guidance and branding. Request a quote through our contact page with your internal size, load weight and quantity, and pricing will reflect that specification.

FAQs about double wall boxes

What are double wall boxes?

double wall boxes are corrugated cartons made from board with two fluted layers and three flat liners. The extra layers give greater stacking strength, puncture resistance and crush protection than single wall board, so they are used for heavy, fragile and valuable goods.

How much weight can double wall boxes hold?

Capacity depends on the size of the box, the board grade and how well the load is packed and spread across the base. Smaller double wall boxes with an even load can carry substantial weights, while large boxes should be packed cautiously so they remain safe to lift.

Are double wall boxes better for storage?

Yes. Their stacking strength means loaded boxes can sit on top of one another for long periods without the lower boxes sagging or collapsing. That makes them a sound choice for warehouse storage, archiving and removals as well as for shipping.

Can double wall boxes be printed?

Yes. Double wall boxes can be printed with logos, product information and handling instructions such as fragile or this way up messages. Clear handling print helps carriers treat the parcel correctly and gives a professional finish to trade and export shipments.