Double Wall Boxes

Double wall boxes for heavy duty shipping, storage and moving

Double wall boxes are heavy duty cardboard boxes made from two layers of fluted board instead of one. That extra layer gives a thicker, more rigid wall, which is why they are the usual choice for heavy items, stacked storage, house moves and parcels that pass through several hands before they arrive.

Packaging Express stocks double wall cardboard boxes in a wide range of sizes, from 178 x 127 x 127mm up to 915 x 915 x 915mm. They are supplied flat packed in packs of 10 to 15, depending on size, and are available for next day delivery.

The sections below explain how double walled cardboard boxes are made, how they compare with single wall, and how to choose the right size for what you are packing.

What are double wall cardboard boxes?

A double wall cardboard box is built from corrugated board with two fluted layers sandwiched between three flat liners. Because the board has five layers in total, double wall boxes are also commonly referred to as 5 ply cardboard boxes.

Packaging Express double walled cardboard boxes use BC flute board, which combines a B flute and a C flute, so you will also see them listed as BC flute boxes. The wall thickness is approximately 7mm. Packaging Express describes this as roughly twice the wall thickness of its regular single wall boxes.

Key specifications:

• Board grade: 125 K/T, with some larger sizes in 150 K/T or 200 K/T
• Flute: BC flute, approximately 7mm thick
• Style: 0201, the standard four-flap box that folds and tapes shut
• Colour: Brown
• Print: Unbranded, with the size and product code printed on the inner flap
• Supplied: Flat packed, in packs of 10 to 15 depending on size

Sizes are listed as internal dimensions, length x width x height. That means the figure you compare against is the item plus any packaging around it, not the item on its own.

What double wall boxes are used for

Double wall shipping boxes

For courier and pallet dispatch, double wall shipping boxes give contents more protection against the knocks, drops and stacking that come with multiple depots. They are widely used by retailers, e-commerce businesses and manufacturers sending heavier goods, and they make sensible cardboard boxes for shipping anything that would be at risk in a lighter carton.

The box protects the load from outside pressure. Anything fragile still needs wrapping and void fill inside, such as bubble wrap, foam or packing peanuts.

Double wall packing boxes for moving house

Double wall packing boxes are widely used by professional removal companies, and they are a good choice of cardboard boxes for moving because they need to survive being lifted, carried, stacked in a van and unloaded, often by people who did not pack them.

A few pointers for a house move:

• Heavy items go in small boxes. Books, records, tools and tins get heavy quickly. A small double wall box stays liftable.
• Crockery and glassware go in small to medium boxes. Wrap each item individually and fill the gaps.
• Bulky, light items go in large boxes. Bedding, duvets and soft furnishings take up space but not weight.
• Tape the base properly. Run tape along the centre seam and across the edges of the bottom flaps before filling.

Heavy duty boxes for storage

Strong cardboard boxes matter most in storage, where cartons can sit under the weight of others for months. The extra stacking strength of double wall board makes it the better choice for warehouse stock, archived goods and anything going into a storage unit.

Being supplied flat packed also means unused boxes take up very little space until they are needed.

How to choose the right double wall box

Four things decide it: size, weight, board grade and how the box will be handled.

Choose the right box size

Measure the item's length, width and height, then add a margin on each side for cushioning and compare that total against the box's internal dimensions, since that is how the range is listed.

Aim for a close fit. Too much empty space means more void fill, more movement and a greater chance of damage. Where an item falls between two sizes, the smaller box usually travels better, provided there is room for cushioning.

Stock sizes run from 178 x 127 x 127mm up to 915 x 915 x 915mm. Where nothing fits, cartons can be made to size, with bespoke printing available for branded packaging.

Consider the weight of your contents

Board strength is only half the question. A large box filled with heavy contents can become too heavy to lift safely long before the board gives way, which is a common mistake when packing books, tools or tinned goods.

Keep dense items in smaller boxes and save the larger sizes for bulky but light contents. If boxes will be stacked, put the heaviest at the bottom.

Choose the right board grade

Most of the range is 125 K/T board, with some larger sizes supplied in 150 K/T or 200 K/T for extra strength. The board grade is listed against each size, so it is worth checking before you order, particularly on the bigger boxes.

All sizes use BC flute at approximately 7mm, so the wall thickness is consistent across the range. The grade is what changes.

Consider how the box will be used

A box going straight into a van for a short move faces different demands from one crossing a courier network or sitting in racking for a year.

• Single journey, handled carefully. A standard grade is usually enough.
• Courier or pallet dispatch. The box is handled repeatedly and stacked with other loads, so board strength matters more.
• Long-term storage. Stacking strength is the deciding factor, as boxes sit under the weight of others for months.
• Repeat use. Check the base flaps and corners before reusing a box, as taping and handling weaken the board over time.

Single Wall vs Double Wall Boxes

Heavy duty packaging boxes for businesses

For businesses, heavy duty cardboard packaging boxes affect how well goods survive the journey, how safely they stack and how much packaging goes into each order.

• E-commerce and retail. Double wall packaging boxes for heavier or higher-value orders, where a lighter carton would risk damage.
• Manufacturing and wholesale. Strong cartons for bulk goods, parts and stock that is handled several times.
• Warehousing and distribution. Boxes that keep their shape when stacked on pallets or racking.
• Removals. Double walled cardboard boxes for household and office moves.

Because the boxes are unbranded, with the product code on the inner flap, they suit businesses that want a plain outer carton. Where branding matters, bespoke printing is available.

Shop Double Wall Boxes

Browse available sizes, compare pack quantities and order double wall cardboard boxes for shipping, storage and moving.

Recycling double walled cardboard boxes

Double wall cardboard boxes in the Packaging Express range are made from sustainably sourced recycled material and are easily kerbside recyclable. Flatten them before recycling so they take up less room.

Boxes used once for a move or a delivery are often in good enough condition to be reused. Keep them flat and dry, and check the base flaps and corners before reusing a box for heavy contents, as repeated taping and handling weakens the board over time.

Frequently asked questions

What are double wall cardboard boxes?

Also called double walled cardboard boxes, they are made from corrugated board with two fluted layers and three liners, which gives a thicker and stronger wall than single wall board. The Packaging Express range uses BC flute board, approximately 7mm thick.

What is the difference between single wall and double wall boxes?

Single wall board has one fluted layer between two liners. Double wall has two fluted layers and three liners. The extra layer makes the boxes stronger, more rigid and better at stacking, which is why double wall is used for heavy goods and longer journeys.

How thick is double wall cardboard?

The Packaging Express range uses BC flute board with a wall thickness of approximately 7mm. Packaging Express describes this as roughly twice the wall thickness of its regular single wall boxes.

How can I tell if a box is double walled?

Look at the cut edge of the board, usually along the top flap. Single wall board shows one row of wavy flutes between two flat liners. Double wall shows two rows of flutes and three liners, and the edge measures around 7mm rather than 3 to 4mm. Double wall board also feels noticeably more rigid when you press the side panel.

What are double wall boxes used for?

Shipping heavier goods, house moves, warehouse storage, stacked stock and courier dispatch. They are widely used by retailers, e-commerce businesses, manufacturers and removal companies.

Do I need double walled boxes for moving house?

For anything heavy or breakable, they are the safer choice, which is why professional removal companies use them. Books, kitchenware, tools and glassware all benefit from the extra rigidity, particularly when boxes are stacked in a van. Lighter belongings such as bedding, linen and soft furnishings can go in single wall boxes.

How much weight can a double wall box hold?

There isn't one fixed weight limit for a double wall box. The safe capacity depends on the board grade, box dimensions, how the contents are distributed and how the box is handled.

Where can I buy double walled cardboard boxes?

Packaging Express supplies double wall cardboard boxes online across the UK, in stock sizes from 178 x 127 x 127mm to 915 x 915 x 915mm, in packs of 10 to 15 depending on size. Orders can be placed online or by phone.

Where can I find cheap double walled boxes?

Cost per box usually comes down to buying by the pack rather than individually, and to choosing a size that fits your product without paying for board you do not need. Our full size range is listed online with pack quantities, so you can compare before ordering. If you order regularly or in volume, contact the team for a quote.

Can double wall boxes be made to size?

Yes. Where a stock size does not fit, cartons can be made to size, and bespoke printing is available for branded packaging.

Buy double wall boxes online

We supply double wall boxes UK wide, from a single pack through to bulk orders for businesses and removal companies. The full size range is listed online by internal dimensions, with the board grade and pack quantity shown for each size, and boxes are available for next day delivery.

Still not sure which double wall box you need?

Tell us what you are packing, its dimensions and weight, and whether it is being shipped, stored or moved. Our team can help you compare sizes and board grades, and advise on whether a stock box or a made to size carton is the better fit.

Call the customer helpline on 0345 224 3691, request a call back, or use the Contact Us form.