Double walled cardboard boxes

Available in a wide range of sizes, our double wall boxes suit everything from bulk postal orders to industrial packing applications. Many sizes are multiscored, giving you the flexibility to reduce box height and eliminate wasted space. Free delivery is available on qualifying orders, with bulk discounts to suit regular, high-volume requirements.

What are double walled cardboard boxes?

Double walled cardboard boxes are a specialist type of packing box made from two distinct layers of corrugated board. This double layer construction is designed to provide significantly greater compression resistance than a single wall equivalent. In fact, they offer significantly greater protection against the forces encountered during shipping, rough handling, and stacking.

The two corrugated layers are securely glued together to form a rigid, high-strength structure. This construction makes double wall boxes ideal for heavier goods and fragile items such as ceramics, glassware, and electronics. They're also suitable for goods that need protection during long-distance transport or extended storage.

Unlike single wall boxes, the additional corrugated layer distributes compression forces across a wider area. This helps protect the contents when boxes are stacked or handled during transit.

Types of double wall cardboard boxes

At Kite, we offer a diverse range of double walled cardboard boxes to meet the packing and shipping needs of most industries. Whether you require a standard box for carrier network use or a heavy-duty solution for industrial shipments, we carry the sizes and formats to match your requirements.

0201 double walled cardboard packing boxes

Our 0201 double walled cardboard packing boxes are the most widely used format across carrier and postal networks in the UK. These are a standard regular-slotted carton (RSC) design, providing a consistent and reliable packing format suitable for most commercial applications. We supply them in an extensive variety of sizes so you can find the right dimensions for your product, without excess void fill or wasted cardboard.

Heavy duty double wall boxes

For goods that are extremely heavy or particularly demanding to transport, our range of heavy duty double wall boxes offers enhanced board grades and higher loading capacity. If your products require more than a standard double wall box, our product experts can recommend a suitable alternative. Options include heavier board grades, extra heavy duty cardboard boxes, or pallet boxes for larger consignments.

Custom sized double wall boxes

When standard sizes do not suit your product, our custom sized box tool enables you to get instant prices on made-to-measure double walled cardboard boxes. This ensures your goods are packed correctly without excess internal space, reducing the risk of movement in transit and the cost of unnecessary void fill materials.

Can a double wall cardboard box be used for fragile items?

Yes. The two corrugated layers provide extra protection for fragile goods and heavier items. They're also ideal for products at risk of compression damage during transit.

Practical applications include:

• Ceramics and glassware - where compression or impact during rough handling is a concern
• Electronics and precision equipment - where internal movement and shock must be minimised
• Heavy items - where a single wall box would deform under load, compromising the integrity of the stack
• Long-distance or international shipments - where goods are handled multiple times across the transit chain

Postal carrier services can also safely stack double wall cardboard boxes without crushing any surrounding parcels, meaning your goods remain protected from dispatch right through to final delivery. For particularly heavy or fragile loads, we recommend distributing the weight evenly within the box and using foam protection or additional void fill materials to further reduce movement.

Can double walled packing boxes be used for large orders?

Double wall boxes are ideal for heavier products that could strain a single wall carton. They're also suitable for businesses shipping multiple items in one consignment. They retain their strength when fully loaded, making them suitable for stacking in warehouses and vehicles before despatch.

Here at Kite, we supply double walled cardboard boxes in bulk quantities, with pricing structured to deliver genuine cost savings for regular, high-volume buyers. Free delivery is available on qualifying orders. If you need guidance on the most cost effective solution for your packing operation, our product experts are available to advise.

How much weight can a double walled box hold?

The loading capacity of a double walled box varies depending on the size, dimensions, and thickness of the corrugated board used in construction. As a general guide:

• Small to medium-sized double wall boxes have a loading capacity of 18–36kg depending on the size of the box
• Larger double wall boxes can typically hold between 27–54kg of evenly distributed weight
• Our smallest double wall box weighs approximately 0.0985kg, going up to 3.2kg for the largest size

These weight figures are a guide, always check that your product first. When packing items, distribute the weight of contents evenly to prevent any single area of the box being strained. If you are shipping particularly heavy items, you may also want to consider reinforcing the box with additional packaging materials such as foam protection, internal liners, or strapping.

Sizes shown are always internal dimensions (length x width x height), and a manufacturing tolerance of +/- 10mm applies. To view the unit weight of your chosen box, select the 'more info' icon in the product table.

Heavy-duty cardboard boxes & pallet boxes

If your products need to withstand heavy loads or extended storage, our product experts can recommend the right packaging solution.

For consignments that exceed the loading capacity of a standard double walled box, we offer:

• Extra heavy duty cardboard boxes - a higher board grade construction suitable for very weighty or awkward items
• Pallet boxes - specifically designed for larger consignments requiring palletised shipping
• Corrugated storage bins - for warehouse organisation and long term storage of heavy components

For most standard shipping needs, however, our double walled cardboard boxes provide an excellent balance of durability, protection, and cost effectiveness. If you are unsure which option is right for your operation, our team is on hand to advise.

How much does a double wall cardboard box weigh?

The weight of a double wall cardboard box can vary depending on several factors, including its size, dimensions, and the thickness of the corrugated board used in construction. As a guide, our smallest double wall box weighs approximately 0.0985kg, with the weight increasing to 3.2kg for the largest size in the range.

When calculating your shipping costs, you will need to account for both the weight of the box itself and the weight of its contents. For precise box weight information, select the 'more info' icon on any product in the table. This is particularly important if your carrier charges by volumetric weight, as the external dimensions of the box will also factor into the calculation.

Are the double wall cardboard boxes environmentally friendly?

At Kite, our double wall boxes contain 60% to 90% recycled material. This makes them a responsible choice for businesses looking to reduce their environmental impact.

These double wall boxes are fully integrated into a circular economy model, significantly reducing the environmental impact your business has on the planet. The durable design helps reduce breakages during transit. This can mean fewer replacement shipments, less waste, and more efficient use of materials.

Kite is a certified carbon neutral company, and our commitment to environmentally responsible packaging extends across our entire product range. If sustainability is a priority in your procurement decisions, our team can advise on the most appropriate eco-friendly packaging options for your operation.