Custom Heavy Duty Double Wall Boxes
BC double-wall shippers rated for heavy parts, glassware and fragile goods with optional partitions.
- BC double wall board
- High ECT ratings
- Partitions and pads available
In short
Heavy duty double wall boxes are corrugated boxes made with two fluted layers and three liners, giving much higher stacking and puncture strength than single-wall boxes. Box Sense makes them from 10 boxes, with production in 8–12 business days after proof approval. Shipping is free to any address in the USA.
About our heavy duty double wall boxes
When a single-wall box bulges, crushes at the corners or fails in a stack, the answer is double wall. Two fluted layers share the load, so the box carries heavy parts, cases of glass, books and equipment, and survives long routes and pallet stacking.
We make double wall boxes in BC and other flute combinations to your size, with partitions and pads where needed, printed with handling marks and your brand, from 10 boxes.
Heavy duty options
Choosing the board
| Board | Best for | Notes |
|---|---|---|
| BC double wall | Heavy and fragile loads | About 6.5 mm; highest strength |
| 48 ECT and higher grades | Heavier loads and tall stacks | Rated for weight and stacking |
| Kraft or white outer liner | Print and appearance | White for brighter printing |
What affects the price of heavy duty double wall boxes
Every box is made to order, so each order is quoted individually. These are the things that move the price most, in order:
- Board. Double wall uses roughly twice the paper of single wall.
- Strength rating. Higher ECT grades use heavier liners.
- Partitions and pads. Dividers and layer pads add material.
- Size. Large boxes use more board.
- Quantity. The unit price falls as quantity rises.
Send your size, quantity and artwork through the quick quote form for a firm price within 24 hours.
When to use double wall
- Contents heavier than about 40 to 65 lb, depending on box size
- Fragile items such as glass, ceramics and electronics
- Boxes stacked several high on pallets or in storage
- Long-distance and multi-carrier shipments
Getting the grade right
Carriers publish weight and size limits for each box grade, and the box maker's certificate printed on the bottom states its rating. Tell us the packed weight and dimensions and we specify a grade that fits within those limits.
How ordering works
- Send your specs. Product size, quantity and artwork (or just a logo). A packaging specialist replies with a firm quote within 24 hours.
- Approve the proof. We send a dieline and a 3D proof so you can see the box before it is made.
- Production. 8–12 business days in our own facility, or 5 days on rush.
- Delivery. Boxes ship flat to you anywhere in the USA, free of charge.
Frequently asked questions
How much weight can a double wall box hold?+
Depending on grade and size, commonly from about 80 lb up to well over 100 lb. We specify the grade to your packed weight.
Can you add partitions?+
Yes, corrugated partitions and pads cut to your product.
Can heavy duty boxes be printed?+
Yes, from handling marks to full branding.
What is the minimum order?+
10 boxes.
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Let's build your heavy duty double wall boxes.
Tell us what you are packing. You will have a quote, a free dieline and a sample plan within 24 hours.