How much weight can a double wall box safely carry?

It depends on the flute combination and box size, but double wall board generally handles loads well beyond what single wall board is rated for, especially where a box sits at the bottom of a pallet stack.

What's the real difference between B/C and B/E flute on a double wall box?

B/C prioritises crush resistance, which matters most on export and pallet-heavy runs. B/E holds most of that strength but gives a smoother face for sharper print, so the choice usually comes down to whether the box needs to look retail-ready.

Do double wall boxes cost a lot more than single wall?

There's a cost difference because of the extra board, but it is usually small compared to what a single damaged pallet or a run of returns costs. Most brands recover the difference quickly once damage rates drop.

What lead time should we plan for on a custom double wall order?

Standard UK production runs 7 to 14 working days once dimensions and artwork are confirmed. Faster turnaround can sometimes be arranged for time-sensitive launches.

Are double wall boxes suitable for export or international shipping?

Yes, this is one of the main reasons brands choose double wall over single wall. The extra flute layer holds up better through the longer transit times and extra handling that export shipments go through.

What printing and finishing options work on double wall board?

Flexographic print works one or two-colour branding on kraft or white board, while litho lamination gives a full-colour, retail-grade finish. A matte or gloss layer is available where the box faces a customer directly.

Is there a minimum order quantity for custom double wall boxes?

Yes, custom runs start from a 100-unit minimum, with volume pricing improving as order size grows.

How do we decide between double wall and triple wall for a project?

Double wall covers most heavy parcel and pallet shipping needs. Triple wall is really a warehouse storage and bulk pallet solution, so it only makes sense once you're storing rather than shipping individual units.

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Double Wall Boxes

Double wall boxes use two layers of corrugated fluting, giving heavier shipments protection against crushing and handling. Hale Path Packaging manufactures every box to order at UK factories, sizing each run to the product's dimensions, from flute selection to printing.