Blog - Your Essential Guide to Double-Walled Cardboard for Secure Packaging

• Two layers of corrugated fluting: Fluting is the layer of cardboard which is formed into a corrugated (wavy) structure. In double-walled cardboard, two layers of fluting are sandwiched between three liner boards.
• Increased shock absorption: This double fluting creates a strong, impact-resistant structure making double-walled cardboard ideal for fragile, heavy or high-value products in particular.

Double vs Single-Walled Cardboard

Double-walled cardboard is often compared to single-walled cardboard and there are a few differences between them. Each has unique structures and varying levels of protection:

• Single-Walled Cardboard: Constructed with one layer of corrugated fluting between two liners, single-walled cardboard is designed for lighter items or goods stored in bulk. Its structure provides basic protection, making it suitable for products that aren’t highly fragile or exposed to intense handling.
• Double-Walled Cardboard: Featuring two layers of fluting and three liners, double-walled cardboard offers reinforced protection. This double layer enhances impact resistance and durability, making it ideal for shipping heavy, high-value or delicate items.

The strength of double-walled cardboard depends on its board grade and flute profile. Board grade refers to the thickness and density of the cardboard, with higher grades providing greater strength and durability for heavier or more fragile products.

Equally, if not more, important is the flute profile, which refers to the wavy, arched paper layers between flat liners. Different fluting is categorised by strength and thickness. For example, BC flute, an industry standard which we supply at Tidmas Townsend, combines what is known as B-flute and C-flute layers for both stacking strength and flexibility, with a thickness of around 7mm which doesn’t pierce easily.

This makes double-walled cardboard versatile enough to protect anything from electronics to heavy industrial parts.

Versatile Protection for Various Packaging Needs

Thanks to its layered construction, double-walled cardboard adapts well to diverse applications, such as:

• E-commerce and Retail: For items needing heavy-duty protection, like glassware or electronics.
• Industrial Use: Durable enough for large or heavy goods that require reinforced packaging.
• Logistics and Fulfilment: For high-value items being shipped internationally from the UK, such as via couriers like DPD to destinations like the USA or Australia.

Double-wall boxes offer the perfect blend of strength, adaptability and reliability, making them an essential choice for businesses focused on secure, damage-free deliveries.

Impact Resistance and Durability

Double-walled cardboard’s layered structure delivers greater impact resistance with the dual layers of fluting and liner boards acting as a cushion. This protects fragile items, such as electronics, glassware or furniture, from vibrations, shocks and compressions during transit.

Product Protection in Courier Systems

Long shipping routes and challenging courier systems, such as DPD or FedEx, often mean items undergo multiple handling points. In these cases, it’s not how heavy or even necessarily how fragile the product is, but how double-walled cardboard boxes can reduce the risk of damage despite frequent transfers.

Better Unboxing Experience

In e-commerce, the unboxing experience is a touchpoint that influences customer perceptions. Sturdy, well-designed double-walled boxes protect products, ensuring customers receive goods in perfect condition. This contributes to a positive unboxing experience, reinforcing brand trust and fostering customer loyalty.

Reduced Costs from Damages and Returns

Product returns due to shipping damage can be costly and affect your business’s reputation. Double-walled cardboard’s resilience minimises these risks, helping businesses avoid the expense and logistical challenges of returns. This is particularly important for companies shipping valuable or fragile items, where replacements or refunds can quickly impact profitability.

• Product Type and Fragility: For lighter, non-fragile items, single-wall boxes can provide ample protection. However, if you’re packing fragile or valuable items, such as electronics or glassware, double-walled cardboard offers an extra layer of cushioning and impact absorption, ideal for preventing damage.
  
  
• Shipping and Handling Demands: How your products are shipped can greatly affect your choice. For example, bulky or fragile items often fare well in single-walled boxes if they’re palletised and shipped together. On the other hand, goods sent via courier systems endure multiple handling points, increasing the need for robust protection.
  
  
• Board Grade and Fluting Profile: Board grade and flute profile are significant factors in box strength. BC flute, the standard for double-walled cardboard, combines B and C flute layers, balancing stacking strength with impact resistance. Heavier-duty double-wall grades offer high durability for items that need extra support, often replacing the need for triple-walled cardboard.
  
  
• Cost-Efficiency: Effective planning around packaging materials can have an impact on your bottom line beyond preventing product damages and returns. Single-walled cardboard is typically more affordable and can be relied on to provide good protection for a wide range of products without the need to invest in double-walled options.
  

Consult with the Packaging Experts

The best way to ensure you’re balancing product protection with affordability and sustainability is by getting an expert opinion. With over 90 years of experience supplying high-quality packaging across a variety of industries, we at Tidmas Townsend can help businesses choose the best solution to fit their needs.

Our team will ask the right questions to understand how your requirements influence the products you need. Contact our team to find out more.

With box sizes ranging from 9x6x6 to 30x20x20, and with an eco-conscious design made from up to 90% recycled content and fully compostable materials, choosing to partner with us ensures your items arrive safely and supports a lower environmental impact.

If you’re ready to invest in high-quality double-walled cardboard, explore our range or reach out to the expert team at Tidmas Townsend. With a diverse selection and commitment to sustainable, durable packaging, we’re here to help you find the ideal solution for your business needs. Contact us for tailored guidance and browse our range of double-walled cardboard boxes today.

Double-walled cardboard is ideal for items requiring extra protection, such as electronics, glassware, furniture and machinery components. Products prone to damage from vibration, stacking or impacts in transit, especially over long shipping distances, are well-suited to double-wall cardboard boxes.

Can I store double-walled boxes in the long term?

Double-walled cardboard boxes are highly durable and resistant to compression, making them suitable for items that need prolonged storage. The extra strength of the double-wall design helps protect stored items from crushing and external impacts, ensuring they stay intact over time.

Can double-walled cardboard be customised?

Absolutely. We offer custom box sizes in double-walled cardboard in addition to custom digital printing. Whether you need to fit your cardboard packaging to specific item dimensions or want to make your brand messaging clear the second your package arrives at its destination, custom double-walled cardboard boxes are an excellent solution.

Is double-walled cardboard recyclable?

Like most cardboard packaging, double-walled cardboard is completely recyclable, reducing your business’s impact on the environment. We go the extra mile to ensure that all of our cardboard products are FSC-certified, giving you and your customers the assurance that they have been responsibly sourced.