In business, there may come a time when you need double walled boxes for shipping.
That’s when ordinary boxes may not be strong enough for the items you want to deliver to your customers.
Also, you may want an extra layer of protection when you’re delivering delicate items.
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If that’s the case, then you want really heavy-duty boxes to use for packaging your items.
The Double Wall Design
The heavy-duty double wall boxes are a lot stronger (often twice as strong) as the regular heavy-duty boxes with just a single wall on each side.
Each wall is constructed with 2 sheets of liner paper pressing on fluted paper sheets inside them.
The liner paper and the fluted paper sheets are usually made of tougher card stock, compared to regular paper.
The material can be eco-friendly Kraft paper (always a popular choice), recycled paper, and even “test paper.
Kraft is the strongest material, due to the use of ‘virgin” fibers.
It’s also the easiest to print on, which is why it’s often used for the liner.
Often, the fluted paper sheets are also corrugated, since the ridges and grooves of the corrugated cardboard boxes are less likely to give in to the weight.
Great for Shipping
So, what’s so special about double wall cardboard boxes for shipping?
Well, this time you have 2 layers of the corrugated fluted paper sheets between the liner papers.
That means you basically double the strength, compared to the single wall design.
When to Use a Double Wall Corrugated Box
You need the heavy-duty double wall for your shipping boxes when you’re not sure that regular boxes will do.
You want these when you have items that are much heavier than usual, even when they’re not that big.
Shipping a coffee machine with lots of plastic parts is one thing.
But shipping a machine with a similar size but made of cast iron will cause problems because of the weight.
For these items, you need a box that can stand up to the weight.
You may want the 2 walls, plus the corrugated cartons.
More Fragile Items
You may want to use these double walled boxes for shipping when the items inside are delicate.
Some even use these boxes for hazardous materials.
If the items inside are sensitive to extreme temperatures, then the double wall design can protect the items from extreme heat and cold from the outside.
These heavy-duty boxes protect the items from outside forces.
The double wall design absorbs impact forces better, so that any glassware inside won’t get damaged.
How to Protect the Contents
Of course, you better pay attention to how you pack and stuff the items inside.
You may want to use lots of padding, bubble wrap, and paper rolls to make sure the items don’t move around, and to absorb any impact forces.
You’ll also want to use specialty tapes designed for these boxes.
These tapes can even work as edge protectors, reinforcing the seams and edges of the boxes along with any middle spots that may bulge.
You should also consider using plastic or a poly bag to keep water from your items (especially books).
You can also use these boxes as your double wall moving boxes.
In fact, if you use these for your customers then you may want to remind them that they can reuse these boxes for that purpose.
You can use these for items that need special protection, such as your electronic items and glassware.
Of course, you can also just use these things for storage, especially for items you won’t use for an entire season.
You may want to put in your winter wear items in these boxes, once summer has come.
Double Walled Boxes for Shipping: Reviews for Top 5 Picks
Which of the available heavy-duty double wall boxes should you go for?
While there are plenty of possible options, you’ll do yourself a favor by starting with these excellent options:
“Boxes for 100-Pound Packages”
Our Rating: 4.5
The pack here gives you 15 double wall boxes to start with, and luckily for you they don’t actually take a lot of space.
That’s because they’re all shipped flat, so you can store these boxes in a cabinet and then take them out when needed.
When you do prop the boxes out properly, then you’ll have a sizable box for your items.
These are literally boxes, since each one measures 16 inches on all the sides.
Of course, this isn’t the only size available for this type of box.
The smallest box available measures only 6 inches per side, while the biggest one has dimensions of 48 by 24 by 12 inches.
Because of the double wall construction, you get twice the protection for your products inside.
Tape Logic actually offers several different types of shipping boxes that suit the particular weight of the products you want to ship.
The 275#/ECT-48 Double Wall Corrugated box is meant for items that weigh 96 to 100 pounds.
If your items don’t weigh as much, you can save on expenses as you can always use the single wall corrugated boxes for lightweight materials.
There’s a stronger (but also more expensive) 350#/ECT-51 Double Wall Corrugated box for items that weigh between 101 to 120 pounds,
For even heavier materials, you’re better off with the triple wall corrugated boxes, as these can deal with weights of up to 300 pounds per package.
Using the Boxes
What you have to keep in mind is that you need to get the right size of boxes beforehand.
That way, you don’t pack the boxes to the max.
If you do this, you risk the contents separating the sides from the inside.
If your products are too small for the box, then you’ll have to use more filling for the box.
Brown Kraft Paper
This uses brown kraft paper, which doesn’t get obviously dirty unlike white boxes.
This is a rather “iffy” issue, because the flat cardboard boxes are just wrapped in plastic cellophane during delivery.
Usually, this is okay as the plastic protects the double walled boxes for shipping against rain and moisture.
But sometimes the cellophane can unwrap so it can get wet.
Also, the plastic cover doesn’t protect from bumps along the way, so that you may have some issues with the edges when you get these boxes.
“For Premium Items / Heavy Tools”
Our Rating: 4.0
This time, we tried the boxes with dimensions of 24 x 18 x 18 inches.
There are also plenty of other size options, ranging from 6x6x6 to 48x24x12.
Just make sure you pick the right size, so that you won’t have to use too much padding if you get something too big.
If it’s too small, then your problems are worse.
Either the product won’t fit, or the item can stress and destroy the box from the inside.
Made of Corrugated Kraft
This one is also made with 275#dw/ect-48 Kraft corrugated.
That means it’s best suited for items that weigh within 96 to 100 pounds.
Of course, you’re also able to use these boxes for items that aren’t as heavy, such as 80-pound printers and other types of electronic equipment.
You’re paying more, but then it may be worth the expense for the reassurance that the boxes are more than strong enough for your products.
The walls are nice and thick, and the seams won’t fall apart.
They sure will protect whatever’s inside, whether you’re using these for storage or for shipping.
In fact, the boxes themselves tend to show hardly any signs of handling.
This may explain why this is a bit more expensive.
The price of a 10-box Partners Brand pack is almost the same as a 15-box Tape Logic pack.
Flat Upon Delivery
These double walled boxes for shipping also come to you stacked flat, so that you save a lot with storage space.
These come wrapped in plastic, which is the SOP for transporting these flattened boxes.
The plastic may not be able to protect the boxes themselves along the way, but then these boxes are meant for strong packaging in the first place.
Just use heavy duty tape to secure these boxes, and you’re good to go.
The recipient may even be able to reuse these boxes for storage when they receive them.
The brown kraft color denotes its eco-friendliness, since a certain percentage of this type of box material is made from recycled paper stock.
The light brown color doesn’t get dirty easily.
It also works well as background should you put in any printing or label on the double walled boxes for shipping.
“Small but Super-Tough”
Our Rating: 5.0
If you’re using a lot of these boxes for your business, then the cost should be considered much more carefully.
This has become popular, since its cost is much less than that of the Partner Brand.
Of course, the main reason why this pack costs about ⅔ the price of the Tape Logic box pack is because it’s smaller.
We opted to check out the boxes that measure 12 inches long, 12 inches wide, and just 10 inches high.
These are great for tool sets that may be compact, but still weigh a lot.
The small size means you don’t need as much packing material to stuff in the box.
The smaller size also makes them easier to handle and carry, though the size may be misleading.
You may want to be sure you can actually carry 100 pounds.
Rated for 96-100 Pounds
Even if the items we shipped for these boxes are smaller, they also weighed close to a hundred pounds.
That’s why we stuck with the heavy-duty 275# D.W./ECT-48 kraft corrugated material for the box.
It’s rated for a weight of 96 to 100 pounds.
These are well worth the price, as the double walled boxes for shipping protect your items on the way to your customers.
You actually have the option of going with the white corrugated or brown kraft box.
We opted for the brown, since any dirt that clings to the box during the delivery won’t be as obvious.
Also, more people know that brown kraft paper is friendlier to the environment, since part of the material is made of recycled paper.
“Terrific for Delicate Glassware”
Our Rating: 4.5
This time we also went with a pack of 10 boxes, and the price is almost the same as the Partner Brand.
But it may be a bit more expensive, when you factor in the smaller size.
We went with the boxes that measured 18 inches on all sides, so it’s a proper cube.
You just need to be careful when you’re putting in your items in these large boxes, because it’s very easy to go over the weight limit.
Since we wanted to compare them on an equal basis, we also picked the 275#/ect-48 double wall corrugated material.
That’s for a weight of 96 to 100 pounds.
You may want to take that into account when you put in books inside, especially when packing hardbound books.
Filling these boxes to the brim with books can certainly go over the 100-pound weight limit easily.
Fine with Heavier Items
We tried these double walled boxes for shipping for heavier items without going over the weight limit, and they did fine.
For electronic items, these are terrific.
Just be careful and have 2 people carrying these boxes, since the boxes may be too bulky for a single person.
Suitable for Delicate Cookware
We were especially delighted at how well these boxes worked for delicate cookware.
Unlike the other boxes we tried which sagged under the pots and pans, these boxes dealt with the weight nicely.
In fact, we even tried to use the boxes for glass dishes, though we were much more careful with the inside stuffing and padding.
We again opted for the light brown color, so that any dirt on it won’t be too apparent.
It’s not too dark, so we can still use black markers to label the boxes.
Recyclable and Reusable
These boxes are also made from recyclable cardboard, though your customers may want to hold off recycling it.
That’s because it works nicely not just as double walled boxes for shipping, but also for storage and for moving.
That should give your brand a nice boost when you use this for packaging your items.
You may want to consider using these boxes as promo materials, with your brand name and logo printed on the box.
Plenty of customers will want to reuse these boxes.
Delivery in Plastic Wrap
These come in plastic wrap, and set flat when delivered.
We didn’t notice any damage when we first received it, which is always a relief.
All in all, we found these boxes tough and able to handle a great deal of weight.
In fact, lots of people consider these boxes truly sturdy.
It apparently can handle a great deal of weight.
So you may want to use a handtruck with it when you need to transport it from one spot to another.
“Great for Books/Musical Instruments”
Our Rating: 4.5
We went back to the Aviditi brand, and this time, got a smaller and flatter box.
We also went with just 10 boxes, since the elongated design is meant for fewer types of items.
This box is 36 inches long, 12 inches wide, and only 12 inches high.
Hopefully, you don’t stand this up, as it may damage stuff inside if it tips over.
The good news is that because of its length, most people have the good sense to set this on its side on the floor or table.
Just don’t over-stuff the box, because the middle of the longer side may bulge as a result.
The size even works for checked luggage, with the normal price for check luggage as it stays within the size requirements.
Made of Corrugated Kraft
Again, we went with the dependable heavy-duty 275# D.W./ECT-48 kraft corrugated material.
These double walled boxes for shipping stood up well to the rigors of shipping.
Even delicate materials remained safe inside during the delivery process.
The weight limit is supposed to be 100 pounds, but be careful that you spread the weight around.
For Books or Musical Instruments
Because of the length, there are certain items here that will fit in perfectly.
We have used these for musical instruments (such as short keyboards), and after going through the mail system the instruments were undamaged and played perfectly.
We’ve also used these for books, and the books that fit inside thankfully didn’t go over the 100-pound weight limit.
The brown color hides any dirt on it, but it’s clear enough for use with black markers.
Double Walled Boxes for Shipping: Conclusion
One survey found that the vast majority of customers pay attention to the packaging.
That’s especially true these days, with the popularity of online shopping.
A typical small business ships via the postal system, so you better make sure your shipping container is up to par.
Your choice can emphasize your corporate sustainability sensibility by using recycled or kraft paper.
You’re also able to make sure your customers get their items undamaged.
With the use of double walled boxes for shipping, you make sure you also take care of your brand reputation!