Double Wall Corrugated Boxes
Heavy-duty 5-ply construction for industrial export and fragile goods - factory-direct from India
Double Wall Corrugated Boxes from Whizzpack
Double wall corrugated boxes use two layers of fluted medium bonded between three liner boards, creating a 5-ply construction that delivers significantly greater compression strength than single wall boxes of the same size. This makes them the preferred choice for heavy industrial goods, fragile items, and products that must survive long ocean freight journeys to the USA, UK, and European markets.
Whizzpack manufactures double wall boxes in BC flute (the most common heavy-duty combination), EB flute for extreme compression strength, and custom profiles on request. All boxes are produced using high GSM kraft liners and tested for ECT (Edge Crush Test) and BCT (Box Compression Test) before dispatch.
Technical Specifications
All specifications are for standard production runs. Custom requirements are accommodated on request - contact our team for a tailored quote.
| Box Style | FEFCO 0201 (RSC), die-cut, or custom style |
| Flute Combination | BC flute (standard), EB flute (heavy duty) |
| Wall Construction | 5-ply (3 liners + 2 fluting mediums) |
| Total Wall Thickness | 7mm (BC) to 8mm (EB) |
| ECT Rating | 44 ECT to 51 ECT |
| Box Compression Test | Up to 700 kgf (on request) |
| Max Load Capacity | Up to 35 kg per carton (design dependent) |
| Liner GSM | 150 - 400 GSM kraft or test liner |
| MOQ | 5,000 units per size |
| Lead Time | 20-28 working days from approved sample |
Key Advantages for US and UK Importers
Superior Compression Strength
BC flute double wall construction delivers 40-60% more Edge Crush strength compared to single wall C flute at comparable weights. Critical for stacked pallets in ocean containers where static loads are sustained for 3-6 weeks.
Vibration and Impact Protection
The double flute layer acts as a shock absorber, reducing transit damage for fragile goods including ceramics, glass, automotive components, and precision machinery parts.
Moisture Resistance Options
We offer water-resistant coated liners and fluting for export shipments passing through humid climates. Wax-coated and VCI (vapour corrosion inhibitor) variants available for metal components.
Recyclable and Biodegradable
All our double wall boxes use paper-based materials. No plastic laminates. Fully recyclable in standard paper waste streams in the USA and UK, meeting Extended Producer Responsibility (EPR) obligations for importers.
Common Use Cases
Our double wall are used across a wide range of industries by importers in the USA, UK, Europe, and beyond.
Frequently Asked Questions
What is BC flute and why is it used for heavy-duty boxes?
BC flute combines B flute (stacking strength) and C flute (cushioning) in a single 5-ply board. The result is a board that resists both compression from stacking and impact damage - making it the standard choice for industrial export packaging.
How much weight can a double wall corrugated box hold?
This depends on box dimensions and liner specification. A typical double wall RSC box (400mm x 300mm x 300mm) with 150GSM kraft liners can safely hold 20-30 kg when properly sealed and stacked on a pallet. We provide load calculations for each order.
Can double wall boxes be custom printed?
Yes. We offer 1-2 colour flexo printing on double wall boxes. For full-colour branded packaging, we recommend our custom printed corrugated box option which covers litho-laminated and CMYK print options.
Do you offer pallet quantities with stretch wrap included?
Yes. We can palletise, stretch-wrap, and affix pallet labels to match your warehouse receiving requirements. Pallet specs (EUR/CHEP/Custom) and carton configuration per pallet can be specified at order stage.
What is the difference between ECT and bursting strength ratings?
ECT (Edge Crush Test) measures how much top-to-bottom pressure a box can withstand before collapsing - relevant for stacking on pallets. Bursting Strength (Mullen Test) measures resistance to puncture. Both metrics are tested and reported for each Whizzpack production run.
Ready to Source Double Wall?
Get factory-direct pricing from our Rajkot manufacturing facility. We supply importers in the USA, UK, Europe, and worldwide with consistent quality and full export documentation.
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