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Double Wall Cardboard Mailer Box

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| SKU: double-wall-cardboard-mailer-box

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    Box Style Self-Locking Mailer Box (Roll End Tuck Front - RETF)
    Material Options Kraft Corrugated, White Corrugated, E-Flute, B-Flute, Rigid Stock (Premium)
    Flute Types E-Flute (1.5mm), B-Flute (3mm), Custom Flute on Request
    Stock Thickness 16pt – 28pt (depending on material selection)
    Printing Options Offset Printing, Digital Printing, Flexographic Printing
    Color Options CMYK (4 Color Process), Pantone (PMS), Inside & Outside Printing Available
    Finishing Options Matte Lamination, Gloss Lamination, Soft-Touch Lamination, AQ Coating
    Add-Ons Spot UV, Foil Stamping (Gold/Silver), Embossing, Debossing, Custom Inserts
    Sizes Custom Sizes Available (Length × Width × Depth)
    Minimum Order Quantity Low MOQ Available
    Turnaround Time 3–4 Business Days (Rush Available)
    Shipping Flat Packed, Free Shipping Available
    Eco-Friendly Recyclable & Biodegradable Options Available
    Product Description
    Maximum paper based protection through combined flute profiles. Double wall cardboard mailer boxes feature two corrugated mediums between three linerboards, creating crush resistance and cushioning performance for heavy, fragile, or high value contents. Engineered for export shipping, industrial components, and extreme handling scenarios. Minimum 100 units, sustainable materials standard.
    Product Detailed Description

    The Physics of Double Wall

    Single wall corrugated resists compression through arch geometry of single flute profile. Double wall combines two profiles — typically B and C flutes — creating synergistic strength exceeding sum of individual components. Crush resistance increases exponentially. Cushioning performance extends across broader impact range. Puncture resistance doubles through linerboard redundancy.
    We manufacture double wall mailer boxes for contents and transit scenarios exceeding single wall capability.

    Construction Specifications

    Flute Combination
    • BC double wall — B flute fine surface, C flute cushioning, standard heavy duty
    • AC double wall — A flute maximum cushioning, C flute stacking, extreme protection
    • BE double wall — B flute strength, E flute print surface, premium presentation with heavy duty performance
    Board Grade
    • 48ECT minimum — Edge crush test rating for heavy loads
    • 61ECT standard — Industrial strength, high stacking, export appropriate
    • 71ECT premium — Maximum paper based protection, extreme contents weight
    Linerboard Options
    • Kraft liner — Natural appearance, standard strength, cost efficiency
    • White liner — Print quality surface, premium presentation, color accuracy
    • Mottled white — Intermediate brightness, print capability, slight texture

    Application Scenarios

    Heavy Contents
    • Industrial components — Metal parts, machinery elements, tool systems
    • Dense products — Books in quantity, tile and stone samples, liquid containers
    • Consolidated shipments — Multiple items combining to substantial weight
    Fragile Items
    • Glass and ceramics — Maximum cushioning for brittleness
    • Electronics — Impact absorption for sensitive components
    • Scientific instruments — Precision protection for calibration maintenance
    High Value Goods
    • Art and antiques — Insurance requirement compliance, provenance preservation
    • Jewelry and watches — Security through structural integrity
    • Collectibles — Condition preservation for investment value
    Export and Extended Transit
    • Ocean freight — Humidity cycling, stacking compression, duration survival
    • Air freight — Pallet stacking, handling stress, pressure fluctuation
    • Multi modal — Transfer between truck, rail, ship, aircraft with varying handling

    Design Considerations

    Weight Penalty
    Double wall adds material weight versus single wall. Evaluate protection value against shipping cost impact, especially for air freight.
    Dimension Precision
    Thicker walls reduce interior dimension for given exterior size. Precise calculation ensuring contents fit without excessive void.
    Print Limitation
    Heavier flute profiles compromise surface smoothness. Lithographic quality challenging. Flexographic or post print labeling more appropriate.
    Assembly Effort
    Increased rigidity requires greater force for folding and closure. Fulfillment labor consideration.

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