Double-Wall Cardboard Boxes

Custom double-wall packaging

Double-wall cardboard boxes offer significantly higher protection for your products during transit compared to single-wall boxes.

Ideal for businesses that ship heavy or bulky products, have issues with product protection in transit or operate in various industrial markets, double-wall boxes maintain their rigidity and shape even after poor handling. The material’s strength also allows the manufacture of extra-large double-wall boxes for oversized products.

At GWP, we are a UK-based manufacturer of custom double-wall boxes with over 30 years of experience. By designing, manufacturing, and printing your double-wall boxes to your exact specifications, you can benefit from improved protection, more efficient shipping, minimised material use, and reduced environmental impact.

No obligation
Free, expert advice
Competitive pricing

Benefits of custom double-wall boxes

By sourcing your double-wall boxes from GWP, you can benefit from:

Extra strong and durable material that accommodates up to 45kg.
Custom sizes and various designs to minimise shipping costs and material use.
A range of different grades – selected by expert designers – plus white or kraft finish.
Excellent stacking strength, perfect for bulk shipping.
Optional printing, including logos, product info, and instructions.
Supplied flat to minimise storage or ready to assemble, reducing packing times.
Use of FSC-certified material, which is easily recyclable.

A person placing items into custom double-wall cardboard boxes on a production line

What our customers say...

Our education packs are very popular with teachers and we have hundreds constantly in circulation going out on loan to schools and then being returned. Because many different individuals reuse the boxes, many times, it is important that it is easy and quick to repack so as to minimise the chance of damage occurring in the repacking process. We’re very pleased with the redesign that GWP did for us, as well as the cost reduction achieved.

Danya Walker | Foundation Executive | Dyson

We’ve been working with GWP for around eight years. They supply all our packaging and we are absolutely delighted with them. Over time our needs have changed and they always respond swiftly with exceptional service.

Mark Barnett | Operations | The Consortium

Have been working with GWP for around 2 years – always a great service, quick turnaround and very competitive pricing. Thank you for all your help!

Ben Bishop | Director | Lumi Plugin

FAQs

What are double-wall cardboard boxes?

Double-wall cardboard boxes are a type of heavy-duty packing box. They use cardboard material with two corrugated layers (hence the double wall) and three liners. The five-ply construction creates a strong and durable box suited to heavier products and transit packaging applications.

What is the difference between single and double wall boxes?

The primary difference between single-wall and double-wall boxes is the material used to manufacture them. Single-wall boxes utilise a single layer of fluting, whereas double-wall boxes use two. Single-wall boxes are generally cheaper and lighter, but double-wall boxes offer additional strength and durability.

Are there different types of double-wall cardboard?

There are several types of double-wall material. The board can vary depending on the outer liners (i.e. weights and colours) and the flute types used. Typical examples are EB and BC flutes, which provide additional strength or improved print quality, respectively. An experienced packaging designer can advise on the best option for your specific requirements.

What is the maximum weight that double wall boxes are suitable for?

Double-wall cardboard boxes can typically carry up to 45kg. However, this can vary depending on the specific grade of corrugated material used, as well as the design and layout of the box itself.

Are double-wall boxes suitable for eCommerce packaging?

While commonly used for industrial transit packaging, double-wall cardboard boxes are increasingly common in eCommerce packaging. With businesses selling a wider range of items through online channels, heavier and bulkier products often require a more robust box for shipping. As they also maintain their shape during transit, parcels arrive looking much more presentable. This improved appearance is particularly beneficial if the packaging has been subjected to poor courier handling.

A person stacking double-wall shipping boxes

Why GWP Packaging?

The outside of GWP Packaging's manufacturing site in Cricklade, Wiltshire

35+ years of experience

Having been in business for over 35 years, we have the skills, people, and, crucially, experience to make significant positive changes to your packaging.

UK packaging experts

We have several teams, working individually and collaboratively, each with specialist knowledge of specific packaging types, materials, and applications.

A team of packaging designers working on a customer brief

Competitive advantage

We can make your packaging work harder for your business, reducing costs, improving performance, and helping with your sustainability goals.

A business you can trust

GWP is part of Macfarlane, improving our geographical reach, resources and product range, whilst maintaining our specialist knowledge and approach.

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