Custom Double Wall Boxes for Heavy and Fragile Goods

What is a double wall box?

Look at the cut edge of a double wall box and you will see two rows of arches, one above the other. That is BC board: a B flute and a C flute glued together, with a liner on each face and a third liner between them.

The result is a wall of about 7 mm. It is stiffer, harder to puncture and far better at taking weight from above than single wall board. It also gives more cushioning between a knock on the outside and the product inside.

Double wall boxes sit within our range of corrugated shipping boxes, and every size is made to order.

Who orders double wall boxes?

Double wall is the board of choice for anyone whose products are heavy, breakable or both. We make it for online shops, trade suppliers and people moving house.

Booksellers use it because paper is dense and splits weak boxes at the seams. Potters and glassware sellers use it for the extra space between product and wall. Wholesalers use it for cases that sit at the bottom of a pallet. Removal and storage customers like it because the boxes last several moves.

Trade buyers sending samples to shops also choose double wall. A crushed box on arrival makes a poor first impression with a new stockist.

What size double wall box should I order?

Start with inside measurements of the product or the stack of products. Then add room for protection. With double wall, you can often use a little less padding than with single wall, because the board itself absorbs knocks.

Keep weight in mind as you size up. A large double wall box can hold more than a person should lift, and a heavy box is more likely to be dropped. Two medium boxes are often safer than one huge one.

Remember that a 7 mm wall makes the outside noticeably larger than the inside. We allow for that when we set the outer size. Our step-by-step box measuring guide covers the detail.

Slotted carton or double wall mailer?

The slotted carton is the workhorse of double wall. It packs deep items quickly, takes tape well and stacks squarely. Most heavy trade orders and house moves use this style.

A double wall mailer folds from one sheet into a tray with a hinged lid. It closes with tabs, so there is no tape to cut. Brands sending heavy gifts, such as stoneware or boxed bottles, like the mailer for its tidy opening. The thick board also gives the lid a solid, quality feel.

Mailers in double wall do take more effort to fold, because the creases are deeper. Allow a little extra packing time when you first switch to them.

Can double wall boxes be printed?

Yes. Most double wall boxes go out in plain kraft with a printed label or one colour logo. That suits the job they do, and keeps the price down.

If you want more, we can print two colour or full colour CMYK on the outside, and print inside as well. A white outer liner gives brighter colour. Lamination, spot UV, foil stamping and embossing are available, though most buyers keep double wall boxes simple. Our designers set up the artwork for free.

Can I add hand holes or inserts?

Hand holes make heavy boxes far easier to lift, and they are a common request on double wall cartons. The thick board around the hole gives a firmer grip than single wall would.

Inside, dividers keep bottles apart, corner pads protect framed goods, and fitted trays hold awkward shapes still. For glass and bottles, our corrugated box divider sets are worth a look.

What mistakes do people make with double wall?

Using double wall for everything is the first. It is heavier and bulkier, so it can raise postage on light items for no gain.

The second is assuming double wall makes padding unnecessary. Board stops crushing, but loose glass can still break if it rattles around inside. The third is oversizing. A huge box packed with heavy goods is hard to lift, and that is when boxes get dropped. Our article on keeping UK parcel postage down explains why box size matters.

How long does an order of double wall boxes take?

We begin with a free digital proof. Once you sign it off, production takes 4 to 6 business days.

Tracked delivery follows within 2 to 3 business days, free to any address in the UK. Double wall boxes come flat, but bundles are thicker than single wall, so allow a little more storage room.

How do I order double wall boxes?

Double wall boxes start from £0.25 per unit, confirmed on a written quote. Share the inside size, style, quantity, print and any hand holes or inserts you need.

Our trade quote form for double wall walks through each point, or try your size in Design Your Box. You can email info@ordercardboardboxes.co.uk or reach the team on WhatsApp. If a box arrives damaged, faulty or misprinted, report it with photos within 10 days for a reprint or refund.