Single wall vs double wall box: what is the difference?

When it comes to packaging, not all cardboard boxes are created equal. One of the most common questions businesses ask is: what’s the difference between single wall vs double wall cardboard? Choosing the right box type is crucial, especially during peak shopping periods like Black Friday and Christmas, when demand is high and the risk of damage during transit increases.

In this guide, we’ll break down the differences between single wall vs double wall box options, highlight their best use cases, and help you decide which type of packaging is right for your business.

A single wall cardboard box is made from one layer of corrugated fluting sandwiched between two sheets of linerboard. It’s lightweight, cost-effective, and versatile, perfect for everyday shipping needs.

Best for: small to medium, lightweight items.
Examples: clothing, books, electronics accessories, beauty products.

Browse DS Smith ePack’s full range of single wall cardboard boxes to see how they can fit standard shipping needs.

A double wall cardboard box has two layers of corrugated fluting and three sheets of linerboard. This makes it thicker, stronger, and far more protective compared to single wall packaging.

Best for: heavier, fragile, or bulkier products.
Examples: kitchen appliances, ceramics, large electronics, industrial goods.

DS Smith ePack offers a robust range of double wall cardboard boxes designed for maximum protection.

This type of box is also commonly used in logistics as a transfer solution. Inside, products are often placed in smaller boxes, making the double wall carton serve as “secondary packaging” for shipping. This is one of the most widespread ways businesses ensure safe handling and transport, particularly for bulk shipments.

When comparing single wall vs double wall cardboard, the choice often comes down to balancing cost efficiency against protection needs.

If you ship lighter items such as fashion, beauty, or books, single wall boxes are ideal. They’re affordable, keep postage costs down, and still offer enough strength for safe delivery.

For heavier goods, or during high-demand seasons like Black Friday and Christmas, double wall boxes provide peace of mind. Their extra protection ensures products arrive intact, even under pressure from stacked pallets or long transit times.

DS Smith ePack also offers versatile packaging solutions, including adjustable height boxes and multiple size options (S, M, L). These make it easier for businesses to adapt to varying order volumes and product types throughout the year.

Choosing between single vs double wall cardboard is only one part of your packaging strategy. Businesses should also think about:

Storage: keeping boxes in good condition ensures they maintain strength.

Functionality: packaging isn’t just about protection—it also represents your brand and customer experience. Explore DS Smith ePack’s insights on packaging features and functions.

During peak season shipping, the risks of damaged goods, lost margins, and disappointed customers multiply. Whether it’s Black Friday flash sales or Christmas gift deliveries, businesses must carefully match packaging strength to the demands of the season.

-Single wall boxes: still suitable for lighter items, but only when paired with protective fillers.
-Double wall boxes: the safer choice for fragile or high-value shipments when order volumes surge.

Planning packaging requirements in advance can save costs and reduce stress during peak shopping spikes.

When it comes to single wall vs double wall, there’s no one-size-fits-all answer. It depends on your products, shipping requirements, and seasonal pressures.

Use single wall boxes for lightweight, everyday items.
Choose double wall boxes for heavier, fragile, or high-value products.
Consider adjustable options for flexibility across different order types.

By selecting the right packaging now, businesses can be well-prepared for busy shopping periods and make sure customers receive their orders in perfect condition.

Explore DS Smith ePack’s extensive range of single wall and double wall boxes to find the packaging that keeps your business strong all year round.