Custom Double Wall Corrugated Boxes

Box Styles in Double Wall Board

The most common style is the regular slotted carton, where four flaps fold in on the top and bottom and are taped shut. It is quick to make up and uses board efficiently. Full overlap cartons extend the outer flaps right across the box, giving a double layer of board on the top and bottom for extra strength when stacking.

Die-cut styles, such as tuck front mailers and boxes with integrated handles, are also possible in double wall. Hand holes make heavy boxes easier and safer to lift. Telescopic boxes, with a separate lid sliding over a base, suit long items and products that need to be lifted out from above. Tall products that need a telescoping lid suit half slotted containers with a cap in the same board.

Sizing Your Cartons Correctly

Corrugated boxes are measured internally as length by width by depth, with length the longest side of the opening. Double wall board is thicker than single wall, so the outside of the box is noticeably bigger than the inside. Measure your product, then add room for protective packing such as bubble wrap, paper or foam corners.

Avoid making cartons much bigger than needed. Empty space allows heavy items to shift and build momentum, which is when damage happens. It also adds to courier charges calculated on size. If you ship many different products, a small set of well-chosen sizes usually covers most orders and keeps your stockroom simple.

Check your courier size limits before you fix the dimensions. Many parcel services charge by volume as well as weight, and a box that is a few millimetres over a size band can cost noticeably more to send. Because double wall board adds to the outside measurement, it is worth calculating the external size on every carton you plan to post.

Printing on Heavy-Duty Board

Many double wall boxes go out plain, but a printed logo turns a utility carton into branded packaging. Flexographic printing in one or two colours is ideal for bold logos, handling symbols and simple text, and it works well on brown kraft liners. For full colour graphics, a white outer liner gives a much brighter result.

Printing practical information directly onto the carton saves labels and time. Handling marks such as this way up, fragile or heavy, along with your web address and a contents panel, help couriers and warehouse staff look after your goods and help customers recognise the delivery at the door.

If you only need branding on part of your range, a printed tape or a single printed label panel on plain double wall cartons can be a sensible halfway point while volumes grow.

• One or two colour logos on kraft board
• Full colour print on white-lined board
• Printed handling symbols and weight warnings
• Blank panels for addresses and contents

Choosing Strength Without Overpaying

Double wall board comes in different grades, depending on the weight and strength of the papers used. Heavier liners give more stacking strength but cost more. The right grade depends on how heavy each box will be, how high they will be stacked and how rough the journey is likely to be.

When you ask for a quote, tell us the typical weight of a packed box, whether it travels by pallet or parcel courier. We then suggest a grade that protects the contents without paying for board strength you will never use. If you are switching from single wall because of damage, describe what went wrong, as it helps us pick the right construction.

Sometimes the answer is a mix. Where the load is light, single wall regular slotted containers cost less and store smaller.

Tell Us the Packed Weight and How High the Stack Goes

Double wall boxes are specified from two numbers most people forget to send: the packed weight of a full box and the number of boxes stacked on top of it on a pallet or in storage. With those, plus the internal dimensions, we choose a flute combination that holds the stack without crushing rather than defaulting to the heaviest grade. Remember that double wall board is thick, so quote internal sizes and let us add the board. Hand holes, partitions for bottles and a tear strip can all be built in, and a full overlap container for pallet loads may suit very heavy goods better than a standard carton.

Send the internal dimensions, box style, packed weight, stacking height and any print, and a custom quote comes by email within one working day. Printed boxes get a free proof so logo size and placement on each panel can be checked. Production takes 4 to 7 working days after approval, boxes arrive flat and strapped by tracked courier to UK mainland addresses, and crushed or misprinted boxes reported within 10 days are reprinted or refunded.