Description
Double Wall Boxes – Heavy-Duty Packaging for Maximum Protection
Double wall boxes are designed for durability, strength, and superior protection. Built with two layers of corrugated board and a fluted middle section, these boxes offer enhanced structural integrity, making them ideal for shipping heavier, bulkier, or more fragile items. At Print Custom Box UK, we specialise in manufacturing custom double wall boxes tailored to your industry needs, branding goals, and shipping demands.
Whether you’re transporting industrial components, fragile electronics, or bulk retail goods, double wall boxes provide reliable support and secure containment throughout the logistics journey. Trusted by businesses across the UK, these boxes are the go-to solution for packaging that requires both resilience and professionalism.
What Are Double Wall Boxes?
Double wall boxes consist of two layers of corrugated cardboard separated by fluting. This design adds an extra level of durability and shock absorption, making them significantly stronger than single wall alternatives. These boxes are particularly well-suited for high-stress situations such as long-distance transportation, stacking in warehouses, or shipping fragile or heavy products.
They are available in various sizes, flute combinations, and printing formats, allowing complete customisation to meet both protective and branding requirements.
Top Uses in the UK Market
Double wall boxes are commonly used in several UK industries:
- Industrial and mechanical parts shipping
- Electronics and tech equipment packaging
- Furniture and home appliance transport
- E-commerce bulk order deliveries
- Archive and storage solutions
- Heavy product packaging in retail and wholesale
- Cross-border and international shipping needs
Key Benefits of Double Wall Boxes
1. Maximum Protection – The dual-layered construction absorbs impact and resists compression, ideal for fragile or high-value goods.
2. Stacking Strength – Perfect for warehouse storage, preventing deformation under load.
3. Durable & Reliable – Withstands rough handling, vibration, and environmental stress.
4. Custom Branding – Despite their industrial strength, these boxes are fully printable to support brand visibility.
5. Cost-Effective at Scale – Reduced product damage results in lower return rates and higher customer satisfaction.
6. Versatile Applications – Suitable for many sectors, from heavy retail to industrial supply chains.
Materials and Construction
Our double wall boxes are crafted from premium corrugated materials:
- Two layers of fluted board (typically BC flute or EB flute)
- Outer and inner liners in Kraft (brown) or white paper
- Moisture-resistant coatings (optional)
- Heavy-duty adhesives for long-lasting bond
Flute options:
- B-flute: excellent crush resistance
- C-flute: ideal for stacking and heavy contents
- E-flute (when paired) for finer print surfaces
All boxes are precision-cut and scored to ensure fast, consistent assembly and structural integrity.
Customisation Options
Our double wall boxes can be customised for both form and function:
- Fully bespoke dimensions to suit your product
- Full-colour CMYK or Pantone printing (inside & out)
- Die-cut handles, ventilation holes, or flap variations
- Branding elements like logos, barcodes, or QR codes
- Matte, gloss, or eco-natural finish
- Custom inserts, dividers, or padding for internal support
Eco-Friendly Packaging Benefits
Sustainability is a core part of our manufacturing process. Our double wall boxes are designed with the environment in mind:
- FSC-certified and recycled board available
- Biodegradable and 100% recyclable materials
- Soy-based and water-based printing inks
- Flat-pack design reduces carbon emissions in transport
- Minimal plastic or glue usage in construction
Choosing double wall packaging from Print Custom Box UK allows your business to maintain environmental responsibility without compromising on strength or quality.
Industries We Serve
We manufacture double wall boxes for:
- Manufacturing and industrial sectors
- E-commerce fulfilment centres
- Electronics and automotive companies
- Furniture and interior decor businesses
- Food and beverage wholesale distributors
- Moving and storage service providers
Why Choose Print Custom Box UK?
- UK-based production with fast turnaround
- Low MOQs and scalable bulk ordering
- Advanced die-cutting and finishing technologies
- Free 3D mockups and in-house design team
- Reliable delivery to London, Birmingham, Manchester, Leeds, and more
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