Custom Double Wall Tuck Top Boxes

Sizing Double Wall Tuck Top Boxes Correctly

Double wall board is thicker than single wall, usually around 6 to 7 mm in total. That thickness eats into the internal space, so always give us the inside dimensions you need rather than the outside size. Measure the product, or the product in its inner packaging, and add a small allowance on each side for any padding or inserts.

Courier size bands matter. Many carriers charge more once a parcel passes a certain length, girth or weight, so a few millimetres can change your shipping cost. If you know the band you are aiming for, tell us and we will design within it. A snug fit also reduces the need for void fill, which saves packing time and material.

For subscription boxes that change contents each month, size around the largest likely combination and use a simple card insert to take up space on lighter months.

Board Grades and Strength

Double wall comes in different flute combinations and liner weights. A BC flute combination is the most common for mail order: B flute gives good print surface and crush resistance, while C flute adds cushioning. For very heavy goods, stronger liners or an EB combination give extra stiffness without making the box excessively bulky.

Outer liners come in brown kraft, white or mottled white. Brown kraft is the most economical and looks natural with one or two colour print. White liners are best for full colour designs and sharp logos.

If you are unsure which grade you need, send a sample product and its packed weight. We can recommend a board that protects it without overspending on strength you will never use. The flute combinations are explained on our double wall corrugated boxes page.

Printing Outside and Inside

The outside of a shipping box takes a lot of punishment, so many brands keep it simple: logo, website and perhaps a pattern or colour band. The inside is where you can be bolder. An inside print, seen when the lid lifts, is a lovely moment for a thank-you message, product care notes or a reorder prompt.

Flexographic print in one or two colours is cost-effective on brown board for larger runs. Digital and litho-laminated print gives full colour photographic quality on white board, ideal for premium subscriptions and gift boxes. A matt or gloss varnish protects the print from scuffs in transit.

Don't forget the practical panels: return addresses, handling symbols and space for a shipping label. Keep the label area plain and on the lid so couriers can scan it easily. The board liners and varnish options page shows white and kraft liners side by side.

Packing Tips for Heavier Orders

Place the heaviest items on the bottom and fill gaps so nothing shifts. Inserts in corrugated board or moulded pulp hold bottles and jars apart. For glass, add a divider so no two items touch. If the box weighs more than a typical parcel, check that the tuck lid is closed firmly and consider a branded tape or sticker seal across the front flap for extra security and tamper evidence.

Test before you commit. Pack a full box, drop it from waist height onto each face and corner, and open it to check the contents. It takes a few minutes and tells you more about your packaging than any specification sheet. Products that need a separate lid rather than a hinged one are covered on our cardboard boxes with lids page.

Drop-Test a Packed Sample Before the Run

The most useful step with a heavy-goods box is a drop test, so ask for a plain sample in the grade we suggest, pack it as you would for a customer and drop it from waist height onto each face and corner. If anything moves or a corner bursts, the flute or insert changes before print. Give us inside dimensions, never outside, because the 6 to 7 mm walls eat into the space, and tell us the packed weight and the courier band you want to stay inside.

Choose ear locks for a firmer close, a peel-and-seal strip for returns, or a tear strip for tamper evidence. Send the dimensions, weight, board preference and artwork, and a custom quote comes back by email within one working day, with simply printed boxes from £0.25 and low minimums quoted per job. The free proof shows the dieline and print. Production takes 4–7 working days after approval and tracked delivery to UK mainland addresses is free, taking 2–3 working days. Damaged or misprinted boxes reported within 10 days are reprinted or refunded. Boxes that open from the front rather than the top are the related double wall tuck front boxes.