Timepack

BC Double Wall

Heavy-Duty Corrugated Boxes and Double Wall Cartons

A heavy-duty corrugated box is usually a double wall carton: two fluted layers bonded together, specified for the weight it carries, how high it stacks and how far it travels. Timepack makes heavy-duty and industrial boxes to your size in BC double wall board, and holds common double wall sizes in stock.

When a box needs to be heavy duty

Move up from single wall when one of these is true of the job.

  • The contents are heavy, dense or shift in the box
  • The cartons stack high in a warehouse or on a pallet
  • The journey is long, or involves several handlers
  • The contents are valuable enough that a crushed box costs more than better board
  • The box is large, so its panels need more stiffness to hold their shape

What makes a corrugated box strong

Strength comes from the board, the construction and the size together, so the same grade behaves differently in a different box. BC double wall is the strongest board Timepack makes: a B-flute and a C-flute bonded together. The liner matters too, and a tall box stacks differently to a flat one of the same area.

The grade is recommended against what the box has to do, because over-specifying board costs money on every box. Describe the weight, the stacking height and the journey, and test a physical sample with your product before production.

How heavy-duty boxes are built

The construction is chosen for the load, not only the board.

  • Stitching or glue: seams are stitched or glued, with long-arm stitching for tall cartons
  • Telescope style: a separate lid and base for deep or heavy contents
  • Maltese cross style: a solid base that cannot open underneath, for large, heavy or knock-down furniture
  • Large boxes: sheets up to 2 750 mm × 1 150 mm

Protecting the load around the box

A strong carton on a poorly secured pallet still arrives damaged. These go around it, and can come on the same order.

Double wall sizes and heavy-duty styles

The stock cartons below are offered in double wall as well as single wall and sold by the bundle. Double wall sheets and the Maltese cross box are listed with them.

Maltese Cross

Maltese Cross

The Maltese Cross Box is a strong and secure packaging solution, ideal for large, heavy or knock-down furniture. Its solid base prevents the box from opening underneath, offering reliable support and protection during handling, storage and transport. The box folds securely around the product and is sealed with tape along the top.

Various existing die sizes are available. This is not a stock item and is manufactured to order; minimum order quantities may apply.

Sizes and options

  • DIE146 - 387X387X12
  • DIE146 - 387x387x12 -
Sheets - Double Wall Board (DWB)

Sheets - Double Wall Board (DWB)

In stock

Double wall corrugated sheets provide superior strength, rigidity and impact resistance for heavy-duty packaging applications. Manufactured with two layers of corrugated fluting, they offer excellent protection for heavy or fragile products and are ideal for pallet layer pads, dividers, box reinforcement, protective packaging and industrial use. sheet sizes and can also be cut to your required dimensions.

Sizes and options

  • BRD36-2.150mx855mm
  • BRD48-1.925mx1.27m
  • BRD63-2.25mx1.66m
Stock 2 - 230mmx150mmx150mm

Stock 2 - 230mmx150mmx150mm

In stock

A versatile corrugated carton ideal for packing, storage and shipping. Perfect for e-commerce orders, small electronics, parts, gifts, cosmetics and general retail products. Available in Single Wall for lighter items or Double Wall for added strength and protection during transit.

Sizes and options

  • Stk2 - 230mmx150mmx150mm (20/Bundle) - Single wall
  • Stk2 - 230mmx150mmx150mm (20/Bundle)- Double Wall
Stock 3 - 250mmx150mmx250mm

Stock 3 - 250mmx150mmx250mm

In stock

A strong and versatile corrugated box ideal for e-commerce orders, bottles, household items, gifts and retail products. Available in Single Wall or Double Wall board to suit your packaging and protection requirements.

Sizes and options

  • Stk3 - 250mmx150mmx250mm (20/Bundle) - Single wall
  • Stk3 - 250mmx150mmx250mm (20/Bundle) - Double wall
Stock 4 - 300mmx230mmx300mm

Stock 4 - 300mmx230mmx300mm

A popular medium-sized corrugated carton ideal for A4 documents, wine bottles, gift packs, electronics, household items and e-commerce shipments. Available in Single Wall or Double Wall board for added strength and protection during storage and transport.

Sizes and options

  • Stk4 - 300mmx230mmx300mm (20/Bundle) - Single wall
  • Stk4 - 300mmx230mmx300mm (20/Bundle) - Double wall
Stock 5 - 450mmx300mmx300mm

Stock 5 - 450mmx300mmx300mm

In stock

A large, versatile corrugated carton ideal for household goods, office files, wine cases, kitchenware, online orders and moving or storage applications. Available in Single Wall or Double Wall board for extra strength and protection.

Sizes and options

  • Stk5 - 450mmx300mmx300mm (20/Bundle) - Single wall
  • Stk5 - 450mmx300mmx300mm (20/Bundle) - Double Wall
STOCK 6 - 600mmX450mmX300mm

STOCK 6 - 600mmX450mmX300mm

In stock

A large corrugated carton ideal for bulk packing, office/home relocations, household goods, archives, e-commerce fulfilment and storage applications. Available in Single Wall or Double Wall board for enhanced strength and protection.

Sizes and options

  • STK6-600mmx450mmx300mm - Single Wall - 15/Bundle
  • STK6-600mmx450mmx300mm - Double Wall - 15/Bundle
Stock 7- 450mmx450mmx500

Stock 7- 450mmx450mmx500

In stock

A large-capacity corrugated carton ideal for moving, storage, household goods, clothing, bedding, bulk shipping applications. Available in Single Wall or Double Wall board for increased strength and protection.

Sizes and options

  • STK7- 450mmx450mmx500 - Single wall (15/Bundle)
  • STK7- 450mmx450mmx500 - Double Wall (15/Bundle)
Heavy-duty boxes at a glance
BoardBC double wall (B-flute and C-flute together)
LinersKraft or white
StylesRegular slotted, telescope, die-cut, Maltese cross
ClosingGlued or stitched, long-arm stitching for tall cartons
Largest sheet2 750 mm × 1 150 mm
PrintingFlexographic, up to 4 colours
Minimum orderFrom ±500 m² of board
In stockDouble wall sizes by the bundle, on ShopXpress

Frequently asked questions

What is the strongest corrugated box?

Of the boards Timepack makes, BC double wall is the strongest. Strength also depends on the liner, the box style and the dimensions, so the grade is recommended against the load, the stacking height and the journey.

What is a double wall box?

A double wall box is made from board with two fluted layers bonded between liners, rather than one. It is stiffer and stacks better than single wall, and is used for heavy contents and rough transit.

How much weight can a double wall box hold?

There is no single figure, because it depends on the box size, the board, how the weight sits and how the boxes stack. Tell Timepack the weight and how it ships, and test a physical sample with your product before production.

Do you have double wall boxes in stock?

Yes. Stock 2, 3, 4, 5, 6 and 7 are offered in double wall as well as single wall, sold by the bundle of 15 or 20 through ShopXpress.

Do you make large boxes for furniture?

Yes. The Maltese cross box is made for large, heavy or knock-down furniture: its solid base stops the box opening underneath, and it folds around the product. It is made to order, in various existing die sizes.

Tell us what you need made

Send us the size, the quantity and what has to go inside it. We will come back with a spec and a price.