Double Wall Corrugated Packaging in North Carolina
The Research Triangle's technology and life sciences ecosystem — anchored by Duke, UNC, and NC State universities and a dense cluster of biotech, pharmaceutical, and technology companies — creates sig
Why North Carolina Businesses Choose Us
Why Choose Double Wall Corrugated
Custom Double Wall Corrugated Packaging | Maximum Compression for Heavy Products
Double-wall corrugated uses two corrugated fluted mediums bonded together with three liner papers (outer liner, middle liner, inner liner), creating a board typically 6-8mm thick with compression resistance far exceeding single-wall corrugated at equivalent dimensions. The double-wall construction distributes compressive forces through two independent fluted medium layers, providing stacking compression resistance exceeding 200 lbs for industrial and freight shipping applications where single-wall corrugated's capacity is insufficient.
Double-Wall Configurations
Double-wall corrugated is produced in multiple flute combinations. BC-flute (B-flute over C-flute, approximately 6.5mm) is the most common double-wall combination. EB-flute (E-flute over B-flute, approximately 4.5mm) provides maximum print quality on the E-flute exterior liner while B-flute inner medium provides structural support -- used for premium retail display requiring double-wall structural performance with near-folding-carton print quality. AA-flute (two A-flute mediums, approximately 10mm) provides maximum cushioning and compression for the heaviest and most fragile products.
Double-Wall Applications
Double-wall corrugated serves applications where single-wall performance is insufficient: industrial freight shipping, bulk product shipping for large appliances, high-stack warehouse storage requiring maximum compression, fragile heavy products requiring both cushioning and compression resistance, and premium retail display requiring structural permanence over extended display periods.
When Single-Wall Corrugated is Not Enough
The decision to specify double-wall corrugated is driven by a single question: does single-wall provide adequate performance for the specific application? For products exceeding 100 lbs, single-wall at standard ECT ratings approaches the limits of its rated load capacity. For warehouse storage with 10+ pallet layers, single-wall compression resistance may be insufficient at the bottom layers under accumulated load. For fragile heavy products requiring both cushioning depth and compression resistance simultaneously, double-wall provides both through its two independent fluted medium layers.
EB-Flute: Double-Wall Performance with Premium Print Quality
EB-flute double-wall corrugated (E-flute exterior over B-flute interior) solves a previously difficult packaging problem: achieving double-wall structural performance alongside near-folding-carton print quality on a single packaging structure. The E-flute exterior liner provides the smooth printing surface that enables lithographic lamination and high-quality flexographic printing; the B-flute interior medium provides the compression resistance and cushioning depth that single-wall E-flute cannot achieve alone.
Double-Wall for Sustainable Heavy Packaging
Double-wall corrugated is sometimes specified as a sustainable alternative to rigid plastic packaging for heavy products -- corrugated's recyclability, recycled content availability, and end-of-life environmental profile are significantly superior to rigid plastics used in industrial packaging. For brands transitioning from plastic crates or foam packaging to sustainable alternatives, double-wall corrugated engineering can achieve equivalent structural performance using recyclable, recycled-content materials.
Custom Cardboard Boxes in North Carolina
Custom cardboard boxes for North Carolina retailers and businesses. Full-color printing for Charlotte, Raleigh, Durham, and all NC cities.
Technology & Research Packaging
Custom packaging for North Carolina tech companies. Premium boxes for Research Triangle Park startups and established tech firms.
Furniture & Home Goods Packaging
Specialized packaging for North Carolina furniture industry. High Point is the furniture capital of the world.
Banking & Financial Packaging
Professional packaging for North Carolina banking and financial services. Charlotte is a major US banking hub.
Craft Beverage Packaging
Premium packaging for North Carolina craft breweries and distilleries. Custom boxes for Asheville beer scene and NC wineries.
Quick Specs
- Minimum Order
- 100 units
- Production Time
- 2-3 weeks
- Free Shipping
- Yes
- Eco-Friendly
- Yes
- Location
- North Carolina
Thickness Options
Industries in North Carolina
Affordable sample kits available
Industries We Serve in North Carolina
We provide double wall corrugated packaging to a wide range of industries across North Carolina.
Double Wall Corrugated is Best For
Available Box Styles
Double Wall Corrugated works great with these box styles.
Tuck End Boxes
The most versatile folding carton style — tuck flaps on both ends create a clean, secure closure for retail and consumer goods packaging
Magnetic Closure Boxes
Rigid set-up boxes with embedded neodymium magnets creating a satisfying snap closure for luxury brand packaging
Sleeve Boxes
Two-piece inner tray and outer sleeve construction creating a controlled sliding reveal for premium product presentation
Pillow Boxes
Curved oval-ended folding carton that creates a distinctive pillow shape for gifts, accessories, and specialty retail
Gable Boxes
Self-erecting folding carton with a distinctive peaked top handle that serves as both closure and carrying mechanism
Two-Piece Boxes
Classic two-component packaging with separate lid and base for premium retail, gift, and apparel presentation
Available Finishes
Enhance your double wall corrugated packaging with premium finishes.
Double Wall Corrugated in North Carolina Cities
We deliver double wall corrugated packaging to cities across North Carolina.
Other Materials in North Carolina
Explore more packaging materials available in North Carolina.
Cardboard
EcoThe universal folding carton substrate -- solid paperboard in 14pt to 24pt weights for retail, cosmetic, food, and pharmaceutical packaging
Corrugated
EcoThree-layer fluted sandwich construction providing superior cushioning, compression resistance, and shipping protection
Rigid Board
EcoDense compressed greyboard for permanent rigid box construction -- the luxury packaging material that never collapses
Kraft Paper
EcoNatural unbleached brown paper with authentic craft character for artisan, natural, and eco-conscious packaging
White Cardstock
EcoBright white coated paperboard providing the cleanest printing surface for vivid CMYK color reproduction
Specialty Paper
EcoPremium specialty papers including textured, metallic, translucent, and decorative stocks for distinctive packaging surfaces
Double Wall Corrugated Packaging in North Carolina — FAQs
What is double-wall corrugated?
Double-wall corrugated uses two corrugated fluted mediums bonded together with three liner papers, creating a board 6-10mm thick with compression resistance exceeding 200 lbs. The two-medium construction distributes compressive forces through two independent layers, providing structural performance far exceeding single-wall corrugated at equivalent dimensions.
What are the most common double-wall configurations?
BC-flute (6.5mm) -- the most common, providing balanced compression and print quality. EB-flute (4.5mm) -- premium print quality at double-wall strength. AA-flute (10mm) -- maximum cushioning and compression for the heaviest applications.
When should I specify double-wall instead of single-wall?
Specify double-wall when: product weight exceeds 100 lbs, warehouse stacking generates compression exceeding single-wall capacity, the product requires both deep cushioning and high compression resistance simultaneously, or the display period exceeds the durability of single-wall at the specified conditions.
Is double-wall more expensive than single-wall?
Yes, typically 40-70% more material cost per unit area due to the additional corrugated medium and liner. The structural performance improvement must be evaluated against this premium for each specific application.
What is the minimum order for double-wall corrugated packaging?
Our minimum order is 100 units for custom double-wall corrugated packaging. Double-wall is compatible with standard flexographic printing and digital corrugated printing at 100-unit minimums.
Do you serve the Research Triangle's biotech and pharma companies?
Yes. Raleigh, Durham, and Chapel Hill's life sciences and technology companies use our professional packaging for pharmaceutical products, health supplements, tech hardware, and consumer health brands.
What North Carolina cities do you deliver custom boxes to?
We deliver free to all North Carolina addresses including Charlotte, Raleigh, Greensboro, Durham, Winston-Salem, Fayetteville, Cary, Wilmington, High Point, Concord, and all rural NC communities.
Do you make packaging for Charlotte's financial and corporate brands?
Yes. Charlotte's banking and financial services community uses our corporate gifting boxes, branded packaging, and professional materials for client programs and corporate communications.
Do you serve North Carolina's craft beer and spirits industry?
Yes. North Carolina's thriving craft brewery and distillery scene uses our custom retail boxes, gift packaging, and branded mailers to sell their products through retail and direct-to-consumer channels.
Can North Carolina food producers get custom packaging?
Yes. North Carolina's pork processors, poultry companies, sweet potato brands, and specialty food producers use our food-safe corrugated and retail packaging for grocery, foodservice, and direct-to-consumer distribution.
Get Double Wall Corrugated Packaging in North Carolina
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