Strong, rigid double wall boxes from stock — delivered fast from our Midlands warehouse

Double wall cardboard boxes are the heavy duty choice for packing items that need extra protection in transit — heavier goods, fragile products, long distance or export shipments, and items that will be stored for extended periods. Our range covers over 20 standard sizes from 152 x 152 x 152mm up to 915 x 254 x 300mm, with multicrease options available for adjustable depth packing. Prices from just 54p per box. Fast UK-wide delivery from our Coventry warehouse.

Need a size that's not in our standard range? We manufacture custom sized double wall boxes here in the UK — call 02476 611234 to discuss your requirements and get a quote.

What is a Double Wall Cardboard Box?

A double wall cardboard box is manufactured from corrugated board with two layers of fluting (the zigzag paper in the middle) rather than the single layer found in standard single wall boxes. This double layer construction gives double wall boxes significantly greater crush resistance, puncture resistance, and stacking strength than single wall alternatives.

Double wall board is typically 7-8mm thick compared to 3-4mm for single wall, and can support loads up to 40kg depending on the box size and board grade. All our double wall boxes are manufactured with at least 75% recycled fibre content, are fully recyclable and compostable at end of life, and are FSC® certified on request.

When to Use Double Wall Rather Than Single Wall

• Heavy items over approximately 15kg — single wall boxes are generally rated to around 15-20kg; double wall handles heavier loads more reliably
• Fragile or high-value goods — the additional board thickness provides better cushioning against impacts and punctures
• Long distance or export shipments — parcels travelling longer distances or internationally encounter more handling and greater risk of damage; double wall provides better protection throughout a longer transit
• High stack storage — double wall boxes have significantly better compression strength than single wall, allowing safer stacking to greater heights in warehouse storage
• Irregular or awkward shaped items — the extra rigidity of double wall board helps maintain box shape around products that don't fill the box completely

Frequently Asked Questions About Double Wall Boxes

What weight can a double wall cardboard box hold?

Double wall boxes can typically hold between 20kg and 40kg depending on the size and board grade. As a general guide, our standard stock double wall boxes are suitable for items up to approximately 25kg. For heavier items, contact us to discuss the right board grade for your application — we can specify heavier board grades for loads up to 50kg and beyond.

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

Single wall boxes have one layer of corrugated fluting between two liner sheets — typically 3-4mm thick and suitable for items up to approximately 15-20kg. Double wall boxes have two layers of fluting between three liner sheets — typically 7-8mm thick and suitable for heavier, more fragile, or more demanding applications. Double wall boxes are significantly stronger but cost more per box than equivalent single wall sizes.

Are double wall boxes the same as heavy duty boxes?

Double wall is one form of heavy duty box — the most common. Triple wall (three flute layers, four liners) is also available for the most demanding applications. Our export RinoHide™ boxes are available in heavy duty double and triple wall grades for international shipping. Call 02476 611234 for heavy duty and export box requirements.

What does multicrease mean on a cardboard box?

A multicrease box has additional score lines on the sides and flaps that allow the box to be cut down to a lower depth — for example a 300mm deep box with multicrease at 200mm and 100mm can be used for items of all three depths. This reduces the number of different box sizes you need to stock on your packing line and minimises wasted space in parcels.

Can I get double wall boxes custom printed?

Yes — we offer custom printed double wall boxes in flexo spot colour from 1,000 boxes, and digital overprinting on our stock range from 200 boxes. Call 02476 611234 to discuss your design and printing requirements.

Do you deliver double wall boxes UK wide?

Most of our double wall range is available for UK-wide next day delivery from our Coventry warehouse. Larger boxes (600mm and above) are marked as local delivery only in the product listings — these are available for collection or local delivery to CV, LE, NN, and B postcodes. For large box requirements outside the Midlands, call 02476 611234 to discuss options.

Our Double Wall Box Range

Standard 0201 Double Wall Boxes

Our most popular double wall format — the standard 0201 style box with four closing flaps top and bottom, sealed with packing tape. Available in a wide range of sizes from small 152mm cubes up to large 610 x 254 x 330mm boxes. Compatible with all standard carton sealing machines and tape guns. Supplied flat packed in packs of 10 or 15.

Multicrease Double Wall Boxes

Multicrease boxes have additional score lines on the sides and flaps that allow the box depth to be reduced by cutting and folding down — a single multicrease box can be used for items of different depths, reducing the number of box sizes you need to stock. Particularly useful for ecommerce operations packing a wide variety of product sizes. Available in several sizes including 225 x 225 x 175mm, 285 x 245 x 295mm, 305 x 229 x 229mm, 305 x 305 x 305mm, 450 x 300 x 300mm, and 450 x 450 x 450mm.

Large Double Wall Boxes

For larger items, we stock double wall boxes up to 915 x 254 x 300mm. Please note that several of our larger box sizes are available to local customers only (CV, LE, NN, and B postcodes) due to their size making national courier delivery impractical — these are highlighted in the product listings below. For large box requirements outside the Midlands, call 02476 611234 to discuss options.

FEFCO Double Wall Box Styles We Manufacture

In addition to our standard stock range, we manufacture custom double wall boxes in the following FEFCO styles from our Midlands production facility — no tooling or origination costs on most styles:

• FEFCO 0200 — Open Top Carton — no lid, ideal for display, automated packing systems, and tray applications
• FEFCO 0201 — Standard Carton — the most common and cost-effective general purpose box design
• FEFCO 0202 — Partly Overlapping Flaps — extra strength on the top and bottom seams; can be used as returns packaging with peel & seal and tear strip
• FEFCO 0203 — Fully Overlapping Flaps — maximum strength for very heavy items; top and bottom flaps overlap completely

Other FEFCO styles available on request — call 02476 611234 to discuss your specific requirements. We can manufacture from as few as 200 boxes in most styles.

FSC® Certified Double Wall Boxes

Datec Packaging is a member of an FSC® certified group (FSC-C004309). FSC® certified double wall boxes are available on request for businesses needing certified sustainable packaging for their supply chain, retail requirements, or EPR compliance commitments. Call 02476 611234 to request FSC® certified boxes.

Custom Double Wall Boxes

If our standard stock sizes don't fit your product, a custom sized double wall box is often the most cost-effective solution. A box that fits your product well uses less board, reduces void fill requirements, and produces a more professional presentation — and the saving in void fill often more than covers the cost difference between a stock box and a custom size.

We manufacture custom double wall boxes from our Midlands facility in a range of board grades from standard BC flute double wall through to heavy duty BCB triple wall for the most demanding applications. Minimum quantities from 200 boxes on most sizes. Bespoke printing available from 1,000 boxes. Call 02476 611234 or visit our UK manufacturing page for more information.

Design and Sampling

The design stage is one of the most important stages in the development of your packaging, it is here that ideas and innovation need to be infused with practical experience to maximise the impact the packaging will have on your potential customers. This is the stage which will determine just how much your packaging will interact with your customer and here at Datec we believe in helping you sell more.

After we have created a perfect design which will grab your customers attention we need to make sure it will work. We provide actual size samples in the correct board grade to check the strength, construction and size of the design to make sure everything fits, and you are completely happy with our ideas.