Skip to content Double-walled corrugated boxes are heavy-duty shipping cartons made with two fluted layers, designed to support heavier loads, improve stacking strength, and protect products during storage and long-distance transportation.
Double-walled corrugated boxes are designed for products that demand higher strength, better stacking performance, and safer long-distance shipping.
Built with two fluted layers between linerboards, these boxes offer significantly more durability than standard corrugated packaging.
For businesses shipping heavier items, fragile goods, or bulk orders, double-walled corrugated boxes help reduce damage, control returns, and maintain product integrity.
At Pioneer Custom Boxes, we manufacture double-walled corrugated boxes for B2B brands, manufacturers, distributors, and small businesses across the USA.
With zero minimum order quantity, free design services, free shipping nationwide, and flexible lead times, we make heavy-duty packaging practical and scalable.
Standard cartons often fail under pressure from stacking, vibration, and repeated handling. A double wall corrugated box solves this problem by adding a second fluted layer, which increases compression strength and impact resistance.
This added structure helps boxes maintain their shape during pallet stacking and warehouse storage. It also protects products from shock during transit.
As a result, double walled corrugated boxes are commonly chosen when single-wall packaging no longer provides enough protection.
Double wall construction typically combines two different flute profiles, such as BC or EB. These combinations balance cushioning and rigidity, allowing the box to absorb impact while resisting collapse.
This structure makes double wall corrugated cardboard boxes suitable for industrial parts, electronics, glassware, machinery components, and bulk shipments.
When shipping conditions are unpredictable or loads are heavy, this construction offers reliable performance.
Box size plays a critical role in shipping safety and cost control. Boxes that are too large increase movement and require extra void fill. Boxes that are too small strain seams and corners.
We manufacture double-walled corrugated boxes in common shipping sizes and fully custom dimensions.
Some businesses request exact formats such as a double wall 15 x 16 x 5 corrugated box for a specific product. Custom sizing reduces waste, improves protection, and supports efficient fulfillment workflows.
The outer liner of a double wall box affects both durability and appearance. Kraft liners provide a natural, rugged look and hide scuffs during shipping. White liners create a cleaner surface that enhances print clarity and contrast.
Both options support the performance of a corrugated box double wall design when matched with the correct board grade. The choice depends on branding needs, handling conditions, and presentation requirements.
Printing allows shipping cartons to double as brand communication tools. We offer digital and offset printing for double-walled corrugated boxes, depending on order size and design complexity.
Digital printing supports short runs and fast updates, making it ideal for testing or seasonal packaging.
Offset printing delivers consistent, high-detail results for large volumes. Both methods support clear logos, instructions, and handling information.
Most printed corrugated boxes use CMYK color for full designs and graphics. Pantone color matching is available when exact brand colors are required.
We accept RGB artwork during the design stage and convert it for print accuracy. Our design team ensures proper bleed, alignment, and layout so graphics print cleanly on heavy-duty corrugated surfaces.
Protective finishes help boxes arrive clean after shipping and storage. Aqueous coating reduces surface scuffing and adds light moisture resistance.
Matte finishes offer a professional appearance, while gloss finishes enhance color vibrancy.
These options benefit brands shipping premium goods, subscription orders, or products that must look presentable at delivery.
Die-cut features add functionality to heavy-duty packaging. Handles improve lifting and carrying. Tear strips allow easier opening. Ventilation cut-outs support airflow when needed.
For advanced functionality, Custom Die Cut Corrugated Boxes allow precise cut patterns without sacrificing strength. These solutions work well for bulky or high-weight products.
If your products are lightweight or shipping conditions are simple, Single-wall Corrugated Boxes may provide enough protection at a lower cost.
For extremely heavy loads or export shipping, Triple-wall Corrugated Boxes offer maximum rigidity and are designed for high compression environments.
For brands needing an intermediate upgrade, Custom 5 Ply Corrugated Boxes balance thickness and performance while improving stacking strength.
We offer zero minimum order quantity on double-walled corrugated boxes, allowing businesses to order exactly what they need. This flexibility supports testing, product launches, and inventory management.
Free design services include dielines, artwork setup, and print optimization. We also provide free shipping across the USA and flexible lead times to support both standard and urgent orders.
If your products require stronger protection and safer shipping, double-walled corrugated boxes are the right solution.
Get a free quote today, request free design support, and order heavy-duty packaging with zero MOQ and free USA shipping.
| Box Style | Double-Walled Corrugated Boxes |
| Dimension (L + W + H) | All Custom Sizes & Shapes |
| Quantities | No Minimum Order Required |
| Paper Stock | 10pt to 28pt (60lb to 400lb) Eco-Friendly Kraft, E-flute Corrugated, Bux Board, Cardstock |
| Printing | No Printing, CMYK, CMYK + 1 PMS color, CMYK + 2 PMS colors |
| Finishing | Gloss Lamination, Matte Lamination, Gloss AQ, Gloss UV, Matte UV, Spot UV, Embossing, Foiling |
| Included Options | Die Cutting, Gluing, Scored, Perforation |
| Additional Options | Eco-Friendly, Recycled Boxes, Biodegradable |
| Proof | Flat View, 3D Mock-up, Physical Sampling (On request) |
| Turnaround | 4 – 8 Business Days, RUSH |
| Shipping | FLAT |
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