Custom Double Wall Corrugated Boxes
Custom double wall corrugated boxes from 100 — two layers of fluting for heavy products, long stacks, fragile goods and export freight, specified by edge crush rating to the load and the journey, printed or plain, in any size.
Two layers of flute, and when the second one pays
- Board
- Double wall corrugated: BC or EB flute, 48–61 ECT or burst-rated
- Styles
- RSC, full overlap, telescoping, die-cut trays
- Plain, 1–2 color flexo, or litho-laminated on EB flute
Get a price for Double Wall Corrugated Boxes
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- Free dielineThe flat drawing comes with the quote, before you commit.
- Proof before pressNothing is printed until you have seen it laid on the dieline.
- Die kept for reordersTooling is paid once. Every reorder skips straight to press.
- Quoted in four marketsUS, UK, Canada and Australia, in the delivery currency.
When single wall stops being enough
- Packed weight above roughly 40 pounds.
- Stacks that sit for weeks in a warehouse or container.
- Export and sea freight, where humidity weakens board.
- Dense products that press on the base: liquids, metal, books.
- Fragile goods where the wall itself is part of the cushioning.
Flute combinations
| BC flute | About 1/4 in thick; the standard double wall for heavy shipping |
|---|---|
| EB flute | Thinner, with a smoother face; prints better, stacks well |
| BC with heavy liners | For the heaviest loads and long stacks |
| Triple wall | For pallet boxes and industrial parts beyond double wall |
Rating the board
Double wall is usually specified at 48 to 61 ECT for stacking, or by burst strength for loads where puncture is the risk. The rating printed on the box certificate should cover your packed weight. We size the grade to the load rather than to the largest option, because an over-specified box costs more on every order and in freight weight.
Send the packed weight, the stack height and how the boxes travel. That is enough to choose the grade.
Styles in double wall
Most double wall boxes are regular slotted cartons, but the board suits other styles too: full overlap boxes for extra base strength, telescoping lid-and-base sets, and die-cut trays. For the standard single wall version, our regular slotted containers in rated board are the starting point.
Double Wall Corrugated Boxes — specification
The rows that are specific to this build first, then what applies to every job we run. Anything not listed is a question, not a limit — send the brief.
This build
- Board
- Double wall corrugated: BC or EB flute, 48–61 ECT or burst-rated
- Styles
- RSC, full overlap, telescoping, die-cut trays
- Plain, 1–2 color flexo, or litho-laminated on EB flute
- Options
- Hand holes, water-resistant coating, partitions
- Marking
- Box certificate with weight limit
- Sizes
- Any size, to the product and the pallet
- Minimum
- 100 boxes
On every job
- Print process
- Flexo in one to four colors straight onto the liner; litho-lamination where the box needs full color or a photograph.
- Color
- Flat colors on kraft. Full color needs a white top liner or a laminated sheet, because brown shifts every color warm.
- Tolerance
- Cutting plus or minus 1.5 mm. The flute compresses, so corrugated runs wider than folding board.
- Tooling
- No die on a regular slotted box, which is cut on a slotter. Die-cut mailers and trays need one, made once and kept.
- Food contact
- Food-grade liners and a vented build where the box carries hot food.
- Sustainability
- High recycled content through liners and flute as standard, and the box recycles whole if it is sealed with paper tape.
- Artwork
- Vector PDF or AI, 3 mm bleed, 4 mm safe area, fonts outlined. We check every file and send a proof before press.
- Dieline
- Supplied free with the quote, before you commit. Yours whether or not you order.
- Sample
- A plain unprinted sample at the finished size on request, for fit and construction.
- Reorders
- Skip the tooling and go straight to press at a lower unit price.
- Lead time
- Quoted with the price against your fill date rather than promised before we have seen the spec.
- Markets
- United States, United Kingdom, Canada, Australia — priced in the delivery currency, freight included.
Boards and films we build double wall corrugated boxes on
Corrugated is a fluted sheet glued between two liners, and the flute decides nearly everything: how it prints, how it dents, how high it stacks. These are the grades we run.
E flute
About 1.5 mm. Prints well and folds crisply; dents under a stack. Retail boxes, mailers and light shippers.
1.5 mm, single wallB flute
About 3 mm. The working default for parcels — takes print reasonably and stacks reasonably. Most shipping boxes are B.
3 mm, single wallC flute
About 4 mm. More cushioning than B, slightly less stacking strength per weight. Common on grocery and produce cases.
4 mm, single wallBC double wall
B and C glued together, about 7 mm. Heavy or fragile goods, pallet stacking, anything over roughly 15 kg.
7 mm, double wallKraft liner
Brown, strong, absorbent. One or two flat colors flexo print well on it; photographs drink into the brown and go muddy.
Outer and inner linerWhite top liner
A bleached outer liner for full-color print on corrugated. Costs more and marks more easily than kraft.
Outer liner onlyRecycled-content corrugated
High post-consumer fiber through liners and flute. The default for shippers; a slightly grayer brown and no loss of strength at grade.
All flutesCoated and water-resistant
A coating or a wax-free barrier liner for damp stores and cold chains. Check the recycling stream before printing a claim on it.
B and C fluteNot sure which? Say what goes in it and where it is sold — the material follows from that. Our notes on recycled, recyclable and compostable cover which claims each stock can honestly carry.
- 01
Send what you have
A dimension, a photograph beside a ruler, or the product itself. No technical drawing needed — that part is ours.
- 02
We quote and draw
A price, a dieline and a date come back together. If a different build would suit the product better, that is in the reply too.
- 03
Approve the dieline
The flat drawing is yours to check: which panel is the front, where the folds fall, how deep the cavity really is.
- 04
Artwork on the dieline
You place your design on the flat we sent, or we place it for you, and you see a proof before anything goes to press.
- 05
A sample if you want one
A plain unprinted sample at the finished size shows fit and construction — the things a drawing cannot.
- 06
Cut, printed, shipped
The die is cut once and kept, so every reorder skips the tooling and goes straight to press at a lower unit price.
Format
Vector PDF or AI where possible. Raster artwork at 300dpi at final size, in CMYK.
Bleed
3 mm past every trim line, so a fraction of drift on the cutter never leaves a white edge.
Safe area
Keep type and anything important 4 mm inside the cut and away from every fold.
Color
Convert to CMYK before sending. Uncoated stock prints lighter; a spot color is the only exact match.
Fonts
Outline them or supply the files. A missing font substitutes silently and the proof will not match.
Barcodes
On a light, matte, unvarnished patch with the quiet zone clear — a code on gloss fails the scanner.
Not set up that way? Send it anyway — fixing a file is a short conversation, and we check every one before press. Our guide to preparing print files covers each point.
Corrugated takes fewer finishes than folding board, and the ones it takes it takes well.
Flexo on kraft
One or two flat colors straight onto brown. Cheap, fast, honest.
Litho-lamination
An offset sheet glued to the flute: full color and photographs on a shipper.
Aqueous varnish
Scuff resistance with no film, so the box still recycles whole.
White top print
Full color flexo on a bleached liner; brighter, and it marks more easily.
Inside print
A second pass on the inner liner — the panel a customer sees first.
Printed tape seal
The brand applied at the last moment, on paper tape that recycles with the box.
Not sure which suits the shelf it sells from? Say where the product is sold and we suggest one — our notes on specialty finishes show them on real boxes.
Sizing a corrugated box against the carrier, not the catalog: double wall corrugated boxes
Corrugated is cut to your internal size, so the box goes round the product rather than the product going into a stock size. That is where the money is: a box 20 mm smaller each way is often a whole postage band cheaper.
- Internal dimensions
- Length, width and depth of the space you need. Board thickness is added outside that, and the flute is thicker than people expect.
- Clearance and void fill
- 5–10 mm a side for a rigid product. Size it properly and you need no void fill at all, which is cheaper and better received.
- Stacking
- Tell us how high the boxes stack on a pallet or a shelf. Edge crush grade is specified from that, not guessed.
- Weight
- The contents weight sets the flute and the liner grade. Over about 15 kg we move to double wall.
- Score allowance
- Corrugated needs more room at the folds than boxboard. The dieline accounts for it; a box drawn from flat dimensions comes out tight.
- Cutting tolerance
- Plus or minus 1.5 mm on corrugated, wider than folding board because the flute compresses.
Not sure your numbers are right? Send the product dimensions rather than the box dimensions and we work the box out — the full method is in our guide to measuring for a box.
Interactive · five steps · no sign-up
Build your Double Wall Corrugated Boxes in 3D
Pick a shape, type a size, choose a board and a finish. The preview on the left redraws as you go, and the spec lands with us exactly as you set it.
Frequently asked questions
Got a question about double wall corrugated boxes? The answers below cover what we get asked most. If yours is not here, send it with a brief, message us on WhatsApp, or call +1 503-461-4788 — we reply the same working day.
What is a double wall corrugated box?
A box with two layers of fluting and three liners, thicker and stronger than single wall.
When do I need double wall?
For heavy loads, long stacks, export freight, dense products and fragile goods.
What is BC flute?
The common double wall combination, about 1/4 in thick, for heavy shipping.
What is EB flute used for?
Double wall that is thinner with a smoother face, good for printing and stacking.
How much weight can double wall hold?
Depending on the grade, well above what single wall carries. We specify it from your packed weight.
Is ECT or burst rating better?
ECT for stacking, burst for puncture risk. Most warehouse loads are specified by ECT.
Can double wall boxes be printed?
Yes, in flexo or litho-laminated on EB flute for full color.
Is double wall good for moving?
For heavy items like books and kitchenware, yes.
Do you make triple wall?
Yes, for pallet boxes and industrial loads beyond double wall.
How are double wall boxes delivered?
Flat and bundled. Double wall bundles are heavier, so we note the pallet weight with the quote.
What is the minimum order for double wall boxes?
100 boxes per size and grade.
What sets the lead time for double wall boxes?
The board grade, since heavier combinations may be run to order. We give a date with the quote.
Same range
More corrugated boxes we make
20x20x20 Cardboard Boxes
100 boxes
Cardboard Boxes
100 boxes
Cardboard Boxes with Handles
100 boxes
Cardboard Boxes with Lid
100 boxes
Corrugated Box Dividers
100 sets
Corrugated Cardboard Inserts
100 inserts
Corrugated Carriers Boxes
100 carriers