The Complete Guide to Double Wall Packaging for Heavy Goods
The definitive guide to double wall packaging for heavy and high-value items.
What is double wall packaging?
Double wall cardboard boxes have two layers of corrugated fluting between three liner papers, creating board approximately 7mm thick. This construction provides roughly twice the strength of single wall, holding items up to 25-40kg and stacking 5-8 boxes high.
Quick answer
Double wall boxes are the standard for items over 15kg, high stacking, and fragile heavy goods. BC flute combination (approximately 7mm) is the default specification. Use for electronics, machinery parts, bulk glassware, and export shipments. Pack with generous void fill and H-tape closure. Stock 2-4 sizes for your heavy product range. Store flat and dry for full strength. The 30-50% cost premium over single wall is justified by the protection requirement.
Key specifications
B-flute outer + C-flute inner, approximately 7mm.
A-flute inner + B-flute outer, approximately 8mm.
Or mixed: kraft outer, test inner.
How to pack heavy items
Heavy-duty packing0 / 5 checked
Details: weight limits or flute grades.
Stacking
Double wall stacks 5-8 high with standard loads. Edge-aligned stacking maximises compression strength. Keep dry: moisture reduces strength by 30-50%. Test your stacking plan with packed boxes for 24 hours before confirming.
Complete double wall range
Heavy-duty boxes from ProcuraPack.
Browse double wall boxesFrequently asked questions
Two fluted layers between three liners. Approximately 7mm thick.
Items over 15kg, high stacking (4+), fragile heavy goods, export.
BC flute with appropriate liner weights.
30-50% more than single wall.
Yes, fully kerbside recyclable.
Part of our guide
Product Guide: Double Wall Cardboard Boxes
Expert guides on double wall cardboard boxes for heavy-duty shipping and industrial packaging.
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