Custom Double Wall Tuck Front Boxes

Construction Details That Matter

A double wall tuck front box is cut from a single sheet of board and folded together, with no glue needed in most designs. Rolled side walls, where the board folds back on itself, give a double-thickness wall around the sides and a smooth, finished edge. Locking ear tabs on the lid hold it shut firmly, and a tear strip can be added for a secure, tamper-evident close that still opens without a knife.

Thumb notches on the front edge make the tuck easy to release. For very heavy loads, a crash-lock base or extra-strength liner grade can be specified. Tell us the packed weight so we choose the right combination.

Rolled walls also protect the edges of the box from crushing when cartons are stacked in a courier van, keeping corners square for the customer. Flute profiles and how they are combined are explained in the board and card types guide.

• Rolled side walls for strength and clean edges
• Locking ear tabs on the lid
• Tear strips for tamper-evident closing
• Thumb notches for easy opening

Inserts for Bottles, Jars and Mixed Products

Heavy items need to stay still. Corrugated inserts with cut-outs hold bottles and jars upright and apart, while folded card platforms raise smaller items to the top so they are visible when the lid opens. For mixed boxes, dividers create compartments for each product.

Inserts can be printed or plain. A printed insert in a brand colour lifts the unboxing; a kraft insert keeps costs down and suits natural brands. Always test a packed box with the heaviest combination of products you will send.

Think about the order in which products are placed. Heavy items belong at the bottom and in the centre, where the base is strongest, with lighter and more delicate items above or around them. A platform insert can separate the two layers, so a heavy jar never rests on a fragile item below it, and the customer sees the lighter, more attractive products first when the lid opens. Divider grids for bottles are drawn up as on the corrugated box dividers for glass page.

Print Inside and Out

The outer surface can be printed in one or two colours on kraft for a clean, cost-effective look, or in full colour on white-lined board for a stronger brand statement. Many brands keep the outside understated and print the inside lid with a message, pattern or product guide, so the reveal happens when the box is opened.

Printing the inner front flap is another good spot, as it faces the customer the moment the lid lifts. A short welcome line, a social handle or a reorder link works well there.

Keep the outside practical as well. Leave a plain area on the top or side for the shipping label so it never covers your logo, and consider a small printed return address on the back panel for parcels that cannot be delivered. Print coverage on brown and white board is compared in the print and finish options guide.

Sizing and Postage Planning

Measure the packed contents, including any inserts and protective paper, and give us internal dimensions. Double wall board is thicker, so external dimensions grow; check them against your courier's size and weight bands before you finalise. A box that fits a cheaper band can save meaningful sums over a year of orders.

If you send several order sizes, two or three box sizes with a shared design often cover most orders and keep packing simple.

Packing speed is worth testing too. A box that folds in one smooth sequence saves time on every order, so make up a few samples with your actual team before you place a large order.

Quote the Internal Size and the Packed Weight Together

Double wall board is thick, around 7 mm per wall, and that trips people up in two directions. Quote us the internal size you need, because an external size will leave the contents 14 mm short in each direction; then check the external size we return against courier bands, since a box that looks like a small parcel inside can tip into the next band outside. Pack a sample order, weigh it and send the weight with the internal size, as the packed weight sets the flute grade and the lid lock.

A custom quote follows by email within one working day with low minimums quoted per job, so a new box can be trialled before the whole range switches. Each order includes a free proof of the flat dieline with inside and outside print marked. Production takes 4 to 7 working days after approval and boxes are delivered flat on a free tracked service to UK mainland addresses in 2 to 3 working days; crushed or misprinted boxes are reprinted or refunded if reported within 10 days. For a lid that folds from the back instead of the front, the double wall tuck top boxes use the same board.