Single vs Double Wall Boxes: How to Choose
Key Takeaway
Single wall boxes suit light and medium parcels; double wall boxes add strength for heavy, fragile or stacked loads. How to tell which your goods need.
Cardboard boxes are made from corrugated board: a wavy layer (the flute) glued between flat paper sheets. The number of fluted layers is the main difference between single and double wall, and it decides how much weight and stacking a box can take.
Single wall boxes
Our single wall boxes use 125KT board with a B-flute: one fluted layer between two liners. They are light, cheap and take up little space when stored flat.
- Good for: everyday parcels, clothing, books, cosmetics, items already in their own packaging.
- Maximum load: shown on the specification sheet on each size (tap the product picture in the range table).
Double wall boxes
Double wall boxes use BC-flute board: two fluted layers stuck together. The extra layer makes the walls stiffer, so the box resists crushing, bulging sides and damaged corners.
- Good for: heavy items, fragile goods, parcels that will be stacked, pallet and export shipments.
- Maximum load: shown on the specification sheet on each size (tap the product picture in the range table).
Stacking: why corners matter
Most of a box's strength when stacked comes from its corners and edges. When boxes sit corner-on-corner in columns, they hold their strength best. Staggered, brick-style stacking makes a pallet more stable, but it puts the corners of the top box over the weaker middle of the box below, so each box carries less. If your pallets are brick-stacked or double-stacked in transit, choose double wall.
Quick decision guide
| Your situation | Choose |
|---|---|
| Light items, sent one at a time by courier | Single wall |
| Items already in a sturdy retail box | Single wall |
| Heavy or fragile goods | Double wall |
| Boxes stacked on pallets, especially brick-stacked | Double wall |
| Export or long-distance freight | Double wall |
Not sure?
Weigh a packed order and compare it with the maximum load on the product specification sheet. If you are close to the limit, or the box will be stacked, go up to double wall.
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