Custom Double Wall Boxes for Heavy, Fragile Shipments

What is a double wall box?

Cut a double wall box open and look at the edge. You will see two rows of arches stacked on top of each other.

That is BC flute. A B flute and a C flute are glued together, with one liner on each face and a third liner sandwiched between them.

The finished wall is about 1/4 in thick. It holds weight from above and shrugs off knocks that would dent thinner board. Every size we make sits in our corrugated and shipping box range.

Who buys double wall boxes?

Anyone shipping goods that are heavy, breakable or both. Etsy potters, Shopify kitchenware stores and wholesale distributors all order them from us.

Book sellers like double wall because paper is dense and splits weak seams. Subscription brands use it for bottle and jar sets. Warehouses put it at the bottom of stacks.

Restaurants and offices order it for storing equipment and supplies. The boxes keep their shape through many trips.

What size double wall box should I order?

Measure the product, or the stack of products, then add space for padding. Double wall absorbs more shock itself, so you can often use less filler than in single wall.

Think about lifting, too. A big box full of dense goods gets heavy fast, and heavy boxes get dropped. Two medium boxes are often the smarter choice.

The thick wall also makes the outside larger than the inside. We handle that when we set the outer dimensions. Our guide to measuring a box shows how.

Should I get a slotted carton or a mailer?

The slotted carton is the everyday choice. It packs deep items fast, takes tape well and stacks square. Most warehouse and moving orders use it.

A double wall mailer folds from one sheet into a tray with a lid that locks shut. No tape is needed, which makes for a tidy unboxing. Gift brands shipping stoneware or bottle sets like it.

Mailers fold with a little more effort because the creases are deeper. Give your packers a day to get used to them.

Can double wall boxes be printed?

Yes. Many buyers keep them plain kraft and add a label or a one color logo. That suits the job and keeps costs sensible.

You can also choose two color or full color CMYK, outside and inside. A white outer liner makes colors brighter. Matte or gloss lamination, spot UV, foil stamping and embossing are available too.

Place your logo in Design Your Box and our designers will lay out the artwork for free.

Can I add hand holes or inserts?

Hand holes are a popular add-on for large cartons. The thick board around each cutout gives a firmer grip than thinner board would.

Inside, dividers separate bottles, corner pads protect frames and fitted trays hold odd shapes still. For glass, browse our corrugated dividers for bottles and jars.

What mistakes should I avoid with double wall?

The first is using it for every order. It is bulkier and heavier, so light items can cost more to ship for no benefit. See our notes on keeping box shipping costs down.

The second is skipping padding. The board stops crushing, but loose glass still breaks if it rattles.

The third is ordering too large. Oversized boxes full of dense goods are hard to carry and easy to drop.

How long does a double wall order take?

You get a free design proof first. Once you sign off on it, your boxes spend 4 to 6 business days in production.

Shipping is free and tracked to any US address, with 2 to 3 business days in transit. The flat bundles are thicker than single wall, so clear a little extra shelf space.

How do I get a quote for double wall boxes?

Pricing starts from $0.30 a box. The exact figure comes in your quote by email within one business day.

Send the inside size, style, quantity, print needs and any hand holes or inserts using our quote request form. You can also call (503) 461-4788, email info@ordercardboardboxes.com or message us on WhatsApp, Monday to Friday, 9 am to 6 pm Eastern.

If a box arrives misprinted, damaged or defective, send photos within 10 days. We will reprint it or refund you.