Heavy-duty protection for shipping, storage and fulfilment. Our double wall boxes add a second flute for extra rigidity, crush resistance and stack strength—ideal for heavier, fragile or multi-item consignments and longer transits.
Choose double wall cardboard boxes when your products need more protection during shipping or storage. These strong cardboard boxes suit heavy, fragile and bulky goods. Pack Exact offers a wide range of sizes for ecommerce, warehousing, distribution and industrial use.
Double wall boxes use two fluted layers between three paper liners. Each layer of corrugated material adds strength and helps the carton resist crushing, punctures and stacking pressure.
These boxes are also known as double walled packing boxes or double wall cardboard packing boxes. Their stronger construction makes them more suitable for demanding journeys than single walled boxes.
Choose double wall for heavier loads, fragile products and longer supply chains. The added rigidity reduces transit damage, helps with pallet stacking and protects multi-item orders packed in one carton.
Their stronger twin-flute construction also provides extra protection when parcels pass through warehouses, couriers and distribution centres.
Heavy or fragile ecommerce orders: extra protection for products moving through courier and fulfilment networks.
Tools, machinery parts and components: suitable for denser products that require a stronger outer carton.
Glassware, electronics and small appliances: pair with protective void fill and bubble wrap.
Multi-item orders and returns: stronger board helps cartons withstand repeated handling and re-packing.
Warehouse stacking and pallet loads: improved crush resistance for storage, pallet transport and courier hubs.
National distribution and longer routes: better performance across courier and 3PL networks.
Long term storage: suitable when cartons are stored in dry conditions and are not overloaded.
Export packing: added durability for multi-leg shipments and repeated handling.
The twin-flute design provides extra protection against knocks and pressure. This helps reduce damage when parcels pass through warehouses, couriers and distribution centres.
Improved crush resistance makes double wall boxes useful for stacking and pallet transport. Always check the total weight and avoid stacking beyond the carton’s safe limit.
Heavy duty cardboard boxes can hold denser products than standard single wall cartons. Common uses include tools, components, kitchenware, electronics and multi-item orders.
The cartons arrive flat for cost effective storage. They are quick to assemble and take up less space before use.
Many boxes contain recycled material and can enter normal cardboard recycling after use. Remove tape and non-paper parts where possible.
Despite their durability, double wall boxes remain affordable and can help reduce breakages and returns when shipping heavier or more fragile consignments.
Measure the internal length, width and height of your product. Choose a close fit while leaving enough room for suitable protective materials.
Use paper void fill, bubble wrap or inserts to prevent movement. Fragile goods may need cushioning around every side. Seal the top and base with strong packing tape.
The correct board grade depends on the product’s weight, shape, route and storage conditions. Extra large products may need pallet boxes or another specialist format.
For more demanding loads, check whether extra heavy duty cardboard boxes or triple wall boxes would provide a safer option.
| Use case | Suggested size (mm) | Notes |
|---|---|---|
| Fragile homeware | 400 × 300 × 230 | Space for wrap + dividers; H-tape base/top |
| Tools / components | 457 × 305 × 305 | Robust outer; add dense cushioning |
| Small appliance | 500 × 400 × 300 | Check volumetric weight with courier |
| Multi-item order | 600 × 400 × 400 | Use partitions/void fill to prevent movement |
Lightweight and cost-effective for everyday parcels and lighter products that do not require the additional strength of double wall cardboard.
Extra rigidity for heavier, fragile or stacked shipments over longer routes.
Pre-scored heights fold down to suit different products, helping reduce empty space and the amount of filling required.
The twin-flute board resists crushing and punctures, protecting fragile contents during handling, shipping and hub stacking.
Better performance across courier, 3PL and multi-leg delivery networks can help reduce damage rates and returns.
Supplied flat for cost effective, compact storage. The cartons are quick to assemble and can be securely sealed with strong packing tape.
Many boxes contain recycled material and corrugated cardboard is widely recyclable. Remove tape and other non-paper materials where possible before recycling.
Double wall boxes provide additional strength without requiring specialist packaging for many applications, helping protect heavier consignments while reducing the risk of breakages.
Small Double Wall Boxes — Perfect for small electronics, parts and accessories that need extra protection.
Medium Double Wall Boxes — Great for books in bulk, kitchenware, office equipment and components where extra rigidity matters.
Large Double Wall Boxes — Suited to heavier or mixed orders, small appliances, kitchenware and industrial goods.
Extra Large Double Wall Boxes — For dense, bulky or oversized products. Always add suitable cushioning and check weight and stacking limits.
Explore the full range: Double Wall Boxes · Need lighter cartons? Single Wall · Reduce void with Multi-Depth .
Double wall boxes are a reliable packaging solution for businesses shipping heavy or fragile items. Their dual-layer construction delivers the strength and stability needed during transit, while supporting cost-effective shipping and storage.
Whether you’re sending machinery components, kitchenware, electronics or multi-item orders, choosing the correct box size and suitable protective packaging can help products arrive safely.
For lighter products, single wall cardboard boxes may provide enough protection with less packaging weight. For products with different heights, multi-depth boxes can reduce empty space and the amount of filling required.
Delivery speed varies by product. Selected double wall boxes held in UK stock are available for next day delivery. Check the individual product information before ordering.
They use two layers of fluted corrugated cardboard between three liners. This creates a stronger carton for shipping, stacking and storage.
Choose them for heavier items, fragile products, longer journeys or parcels that may experience repeated handling.
Yes. Corrugated cardboard is widely recyclable. Remove tape and other non-paper materials where possible before recycling.
Yes. Use suitable cushioning and void fill to stop products moving, especially when packing fragile or valuable goods.
Use strong packaging tape and apply an H-tape pattern across base and top flaps.
Yes, if they remain dry and are not overloaded. Store them away from moisture and avoid excessive stacking pressure.
Custom sizes and printed cartons may be available for larger orders or specialist packaging requirements. Contact us to discuss your requirements.