Double Wall Tuck Top Boxes.

Two layers of fluting are laminated together between the liners, usually in a BC or EB combination. The board ends up with roughly double the edge crush of single wall. That is a big step up, and it comes with more board, more weight and thicker walls.

BC is the heavy-duty standard. EB puts the finer E flute on the outside, which gives a better surface for print.

Double wall pays for itself when boxes sit at the bottom of a pallet for days or ship overseas. Stacking strength is what it buys. Heavy or valuable goods, long routes and rough handling are where it earns its cost, and for export it's often the sensible minimum.

For light goods it is usually over-specified. A single wall box with good void fill often gives the same protection for less money.

The walls are thicker, so the box grows on the outside for the same space inside. We size to the internal dimensions your product needs and allow for the board thickness on every panel.

That matters for freight, since carriers bill on dimensional weight. Common double wall builds include 10 × 8 × 4 in and 14 × 10 × 6 in, and anything else is made to order.

Yes, the blank is stiffer and needs deeper creases to fold cleanly. Shallow creasing on double wall board cracks the liner along the fold and makes the packer fight every flap. We cut these with deep-crease tooling and confirm the folds on a sample before the run.

Ask your packing team to fold a few samples with the real product inside. They'll know within minutes whether the tuck top closes without a struggle.

Flexo direct print is the standard, and a litho-laminated face is the step up for presentation. Flexo prints straight onto the kraft liner and handles logos, line art and handling marks well. Litho-lamination bonds a printed sheet to the outer face, which allows full colour plus finishes like foil or spot UV.

Whichever you pick, we'd print weight and this-way-up marks on at least two sides for the people stacking it.

Yes, the board goes into ordinary corrugated recycling. Recycled fluting is standard on these builds and the content is high, with strength-grade kraft used for the outer liners. A flexo-printed box is fibre all the way through.

A plastic lamination film on a litho face is the one addition that makes recycling less straightforward. If the recycling message is printed on the box, skip the film and stay with ink or an aqueous coat.

We start double wall tuck boxes at 500 units. Heavy-duty programmes often run well past that, up to 100,000. Since these ship flat, a first order takes up far less warehouse space than the erected size suggests.

If you're weighing single against double wall, ask for both prices at 500 and compare them next to the damage rate you're seeing now.

Plan on 7 to 10 business days after artwork sign-off. A rush run shortens that to 5 to 7 business days.

Before bulk, a sample in the chosen board arrives in 5 to 7 business days, and we recommend loading it and stacking it the way it will actually ship. You get the sample fee back as a credit on the bulk order.