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Custom Double Wall Cardboard Boxes

Manufacturers, wholesalers and online sellers of heavy goods choose these cartons when a load must survive pallet stacking and courier sorting yet still arrive square. The deciding factor is the flute pairing, BC for stacking strength or EB for a slimmer printable wall, matched to your packed weight and stack height.

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opening When does a shipment need a double wall board?

Aly Packaging manufactures double wall cardboard boxes for UK manufacturers, wholesalers, removal firms and online sellers of heavy or fragile goods. Two fluted layers between three liners give the wall its depth, and the flute pairing is the decision that matters. BC flute, around 6 to 7mm thick, carries the heaviest stacking loads and absorbs knocks well. EB flute, nearer 4 to 5mm, trades some stacking strength for a smoother face and less storage space. We choose between them using packed weight, stack height and how long cartons sit in the warehouse, and quote both if the call is close.

Stack height sets the board grade, not product weight alone

Bottom cartons on a pallet carry everything above them, sometimes for weeks, so the board is sized from the stack rather than from one box. Edge crush (ECT) values for the liner and flute combination give an estimated box compression strength (BCT). That figure is then discounted for damp storage, long dwell times and any overhang past the pallet edge, because each one weakens corrugated. Liners are specified by weight and type, for example a kraft outer for wet strength with a test liner inside. Column stacking, with corners aligned, holds considerably more than an interlocked pattern. For heavy or high-value runs, a sample can be compression tested before production starts. Share your pallet pattern and we will check the grade against it.

Amazon FBA, Parcelforce or a pallet network: which limits apply?

Every route into the UK market puts different limits on the same carton. Amazon UK's FBA inbound rules cap a standard box at 23kg and 63.5cm on any side, and from 15kg they ask for team-lift labels on the top and sides, so weight and size need settling at dieline stage. Courier networks such as Parcelforce, which takes parcels up to 30kg, and DPD run cartons through conveyor sorters that drop and turn them, which favours BC flute with glued or taped seams. Pallet networks such as Palletways deliver into retailer distribution centres on 1200 x 1000mm pallets, where the carton footprint should divide neatly into the deck. We specify flute, liner grade and footprint to the route each carton travels.

An unmarked heavy carton becomes a manual handling risk

A back injury in a goods-in bay often starts with a box that looked lighter than it was. The Manual Handling Operations Regulations 1992 require employers to reduce lifting risks and, where reasonably practicable, to tell staff the weight of each load and its heaviest side when the centre of gravity is off-centre. That duty sits with whoever employs the people lifting, yet the carton is the easiest place to carry the information. Our artwork adds a printed weight panel, a heavy-side arrow and die-cut handholds before production begins, placed high on the end panels and clear of the corners so they cost as little stacking strength as possible. Where the carton also sells from a shelf, litho-laminated print on EB flute is possible, although it adds a cost that freight-only cartons rarely justify.

Materials

  • BC flute double wall, around 6 to 7mm, for heavy stacking and long freight
  • EB flute double wall, around 4 to 5mm, for a slimmer wall with a smoother print face
  • Kraft outer liners for wet strength, with test liners inside to control cost
  • Corrugated partitions and fitments that separate glass, parts or fragile items

Finishes

  • One or two-colour flexo on brown kraft for logos and handling marks
  • White-top liner where brand colours need to read accurately
  • Litho-laminated print on EB flute for cartons that double as retail packs
  • Die-cut handholds, tear strips and printed weight panels

Three numbers price a double wall carton accurately

Packed weight, stack height and delivery route come first, followed by internal dimensions and quantity. Manufacturers, wholesalers, Amazon FBA sellers and removal or storage firms then receive a recommended flute and liner grade, with handholds and weight marks shown on a digital proof. Low minimum quantities allow a pilot batch to be stacked and shipped before a full run. Standard turnaround is 10 to 12 business days from artwork approval, with a rush option in 6 to 8 business days. Contact us at sales@alypackaging.co.uk or call +447462212450.
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What Makes Us The Top Supplier?​

Top quality prints using the latest technology

We are commercial printers with experience in Litho,
Digital, and off-set printing techniques.

Fully Personalised sizes and designs

We specialise in manufacturing bespoke boxes in
custom size and shape of your choice.

Quick Turnaround

With our printing setups across the globe, we are
capable of handling small and bulk orders alike.

Flawless Finishing with Prime Results

Aly Packaging is mainly a B2B supplier, we believe in delivering the best of the best.

Dedicated Packaging Consultants

Our dedicated team of packaging consultants are
there to help you from start to finish.

Environmentally friendly production processes

Our eco- friendly cardboard, kraft, corrugated, and rigid boxes are produced in a controlled environment.

Customise Your Custom Double Wall Cardboard Boxes

Select Key Features & Finishes

  • Dimensions
    Custom Sizes: We only manufacture bespoke boxes. You can order your custom printed boxes according to your preferred shapes and sizes.
  • Minimum Order Quantity
    MOQ: The minimum order quantity you can expect from us is 50 Boxes.
  • Paper Stock
    Paper Stock: 250Gsm to 500Gsm (14pt to 28pt) Eco-friendly White Card or Brown Kraft, B, C, or E-flute Corrugated, or 800Gsm to 1400Gsm Rigid Hardboard.
  • Printing
    Printing Method: 1-4 Colour CMYK or Pantone Colours - Off-set, Digital, or Screen Printing – Outside or Both Sides
  • Sampling
    Sampling: Free Digital Proofing. Material Sampling and Prototype Sampling is Provided on Demand.
  • Turnaround
    Production Speed: Standard 10 Business Days, Priority 8 Business Days, Rush 6 Business Days.

Rush Order Service

We truly understand that everything is not standard so our expedited plan of 04 working days is the solution to your rush requirements. Fill below form and get instant response from one of our packaging experts.

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