Three liners
The outer, central and inner liners hold the board together and provide smooth protective surfaces around both fluted layers.
Please note that all box dimensions quoted refer to the internal measurements of the box.
Please note that all box dimensions quoted refer to the internal measurements of the box.
Box Material Guide
Double Wall Cardboard – Stronger Protection and Better Stacking
Double Wall cardboard is a stronger corrugated material designed for heavier products, increased stacking and more demanding shipping conditions. Its two fluted layers provide additional rigidity, cushioning and resistance against compression compared with standard Single Wall cardboard.
What is Double Wall cardboard?
Double Wall cardboard is made from five paper layers: an outer liner, two corrugated fluted layers, a central liner and an inner liner. These additional layers create a thicker and more rigid board structure.
It is commonly used for made-to-measure boxes that need to carry heavier goods, withstand increased stacking pressure or provide improved protection during storage and transportation.
Why customers choose Double Wall
- Stronger than standard Single Wall cardboard
- Improved resistance against crushing and compression
- Better suited to heavier products
- More reliable for stacked storage
- Improved protection during delivery and handling
- Available in made-to-measure sizes
- Suitable for many industrial and commercial products
How Double Wall cardboard is constructed
Double Wall combines two corrugated layers with three flat liners to create a stronger and more protective board.
Two fluted layers
Two wave-shaped corrugated layers create additional cushioning, rigidity and resistance against crushing.
Thicker structure
The five-layer construction produces a thicker board that offers greater support for demanding packaging applications.
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Key features and benefits
Double Wall is suitable when standard cardboard does not provide enough strength, stacking performance or protection.
Stronger protection
The additional fluted layer helps protect products against impacts, pressure and movement during handling.
Better stacking
Improved compression resistance makes Double Wall more suitable for boxes that will be stacked in storage or during transportation.
Suitable for heavier goods
Double Wall provides a stronger structure for products that are too heavy or demanding for standard Single Wall packaging.
Improved cushioning
The two fluted layers create additional air spaces that help absorb shocks and reduce movement.
More rigid
The thicker board helps the finished box retain its shape under pressure and during repeated handling.
Made to measure
Custom dimensions improve product fit while reducing unnecessary empty space and excess internal packaging.
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Double Wall is suitable for
- Heavier products and components
- Fragile goods requiring improved protection
- Boxes stored in higher stacks
- Industrial and engineering products
- Machinery parts and tools
- Household appliances and equipment
- Longer journeys and repeated handling
- General export and distribution packaging
Consider a heavier material when
- The contents are extremely heavy
- The product is highly valuable or sensitive
- Boxes will experience severe stacking pressure
- The journey involves demanding industrial handling
- The box needs exceptional puncture resistance
- The product requires maximum structural strength
- The packaging is intended for extreme export conditions
Typical products packed in Double Wall boxes
The correct material depends on the packed weight, box dimensions, product fragility, stacking height and transport conditions.
Machinery parts
Components, mechanical parts and tools that require improved support during storage and delivery.
Electrical equipment
Packaged electronics, appliances and equipment that benefit from increased cushioning and rigidity.
Glass and ceramics
Fragile goods used with suitable internal cushioning, dividers and protective packaging.
Automotive components
Vehicle parts, accessories and packaged components requiring stronger outer protection.
Bulk retail goods
Multiple products packed together for distribution, storage or warehouse handling.
Industrial supplies
Heavier commercial products, hardware and general industrial items.
Double Wall material overview
This overview can help determine whether Double Wall is suitable for your packaging requirements.
Protection level
Stronger protection for heavier and more demanding products.
Construction
Three paper liners with two corrugated fluted layers.
Stacking performance
Improved compression resistance compared with Single Wall.
Typical use
Industrial goods, heavier products, storage and distribution.
How Double Wall compares with our other materials
Double Wall offers a balance between everyday packaging and heavier-duty protection for demanding products.
| Material | Protection level | Best suited for | Relative weight |
|---|---|---|---|
| Single Wall | Standard protection | Lighter products and everyday packaging | Lightweight |
| Double Wall | Stronger protection | Heavier goods, improved stacking and fragile products | Medium |
| Tuff Wall | Extra heavy-duty protection | Demanding industrial and distribution requirements | Heavy |
| QuadBoard | Maximum premium protection | Very heavy, valuable or highly demanding applications | Very heavy |
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When should you choose Double Wall?
Choose Double Wall when your product requires more protection than standard Single Wall cardboard can provide.
It is particularly suitable for heavier products, fragile goods, stacked storage and deliveries involving repeated handling.
What should you consider?
- The total packed weight of the box
- The size and shape of the product
- How fragile or valuable the contents are
- The expected stacking height
- The length and method of transportation
- The amount of internal protective packaging
- How often the box will be moved or handled
Double Wall cardboard questions
Common questions about choosing and using Double Wall packaging.
Is Double Wall stronger than Single Wall?
Yes. Double Wall uses two corrugated fluted layers and three liners,
creating a thicker and more rigid board structure.
Is Double Wall suitable for heavy products?
It is suitable for many heavier products, although the correct material
depends on the packed weight, dimensions, stacking and handling conditions.
Can Double Wall boxes be stacked?
Double Wall generally offers improved stacking and compression resistance
compared with Single Wall cardboard.
Is it suitable for fragile products?
Yes, when used with appropriate internal protection such as inserts,
dividers, cushioning or void filling.
Can Double Wall boxes be made to measure?
Yes. Our Double Wall boxes can be manufactured to the internal dimensions
required for your product.
When should I choose Tuff Wall instead?
Tuff Wall should be considered for particularly heavy goods, demanding
industrial handling, higher stacking pressure or applications requiring
extra heavy-duty protection.
Order made-to-measure Double Wall boxes
Enter your required box style, internal dimensions, material and quantity into our online calculator to receive an instant made-to-measure box price.