Board Specifications: Finding Your Perfect Strength
Choosing the right material isn’t just about the box, it’s about the journey your product takes. If the board is too thin, the box collapses. If it’s too thick, you’re paying for unnecessary weight. Here is our "No-Jargon" guide to getting it right:
Single Wall vs. Double Wall
Think of this as the "Base Layer" of your packaging.
Single Wall (3 Layers): A single layer of corrugated "fluting" sandwiched between two liners.
Best for: Lightweight items, e-commerce "unboxing" experiences, and products that are already sturdy (like books or clothing).
Weight Guide: Generally safe for items up to 5kg – 10kg.
Double Wall (5 Layers): Two layers of fluting. This is significantly stronger and provides a "cushioning" effect.
Best for: Heavier goods, fragile items, and anything being sent via international courier.
Weight Guide: Essential for items from 10kg up to 25kg+.
The "Flute" (The Wiggle in the Middle)
The "Flute" is the corrugated bit between the cardboard sheets. The height of that wiggle changes how the box performs:
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E-Flute (Fine): Very thin and flat. It’s perfect for high-quality printing and retail boxes where you want it to look sharp, not "industrial."
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B-Flute (Standard): The most common choice for shipping boxes. It offers great crush resistance and is easy to fold.
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BC-Flute (Heavy Duty): A combination of two flutes. This is the "Gold Standard" for exporting and stacking high on pallets.
Selection Guide: Weight vs. Shipping
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Lightweight (0–5kg): For items sent via Royal Mail or standard Courier, we recommend Single Wall (B-Flute).
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Medium (5–12kg): For items sent via DPD or dedicated Courier networks, we recommend Single Wall (Heavy Grade).
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Heavy (12–25kg): For heavy-duty shipping or International transit, we recommend Double Wall (BC-Flute).
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Fragile or High-Value: Regardless of the shipping method, always use Double Wall for the extra cushioning and crush resistance it provides.
Why "Board Grade" Matters for Your Bottom Line
Using the right grade doesn't just protect your product—it protects your reputation.
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Reduce Returns: Stronger board means fewer damaged goods.
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Lower Shipping Costs: Optimizing board weight can keep you in a lower courier price bracket.
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Sustainability: We help you choose the lightest grade that still does the job, reducing waste.
Choosing Your Material & Strength
Getting the right box goes beyond size. Before you finalise your order, ensure you've optimised for cost and protection. Still Unsure? If you have a specific product like a heavy machine part or a delicate glass bottle, tell us the weight and dimensions. We’ll calculate the exact "Burst Strength" required so you don't have to. If you need clarity on board strength, printing options, or shipping efficiency, our experts are here to help you get the exact specification needed for your product's journey.
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Single Wall vs. Double Wall
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The "Flute" Grades (E, B, and BC).
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The Weight & Shipping Table.
Ready to choose your box style?
Standard Cases & FEFCO Based Designs
The Foundation of Efficiency and Reliability
Our core product line is built upon the globally recognized FEFCO-ASSCO International Style Guide, ensuring every standard box delivers proven performance, consistency, and rapid lead times. This range covers all common shipping and storage box types used for high-volume, general-purpose logistics.
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Ideal for: High-volume warehousing, stock storage, and palletized transport.
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Key Features: Proven structures (0201, 0409), optimal strength-to-weight ratio, and cost efficiency.
E-Commerce & Retail Presentation
Maximizing Brand Experience and Safe Transit
This range focuses on consumer-facing packaging designed to excel in the unboxing experience while withstanding courier transit. We offer innovative structures that reduce internal movement and enhance visual appeal directly to the customer.
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Ideal for: Subscription boxes, direct-to-consumer (D2C) shipping, and retail-ready display packaging.
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Key Features: Mailer designs, easy-open strips, custom display windows, and product-cradling fitments.
High Performance & Speciality Formats
Engineered for Extreme Conditions & Compliance
Engineered for Extreme Conditions and Compliance When standard cases aren't enough, this category provides solutions for products requiring extra protection, specific compliance, or specialized storage. These are proven designs for the toughest logistics challenges.
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Ideal for: Heavy goods, thermal (temperature-sensitive) products, export shipments, and long-term archive storage.
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Key Products: Archive Boxes, Export Grades, Produce Trays, Squbes, and Thermal Packaging.
Ready to Order? Don't Guess on the Details.
Getting the right box goes beyond size. Before you finalize your order, ensure you've optimised for cost and protection. If you need clarity on board strength, printing options, or shipping efficiency, don't hesitate to reach out. Our experts are here to help you get the exact specification needed for your product's journey.
Fully Custom Engineering for Unique Challenges
This is our complete structural design service. Our team engineers solutions from scratch to solve highly complex problems, integrating unique materials, custom closures, and precise geometries to achieve absolute product security or distinct retail presence.
Ideal for: Products with unique geometries, fragile industrial components, or high-end gift sets demanding proprietary designs.
Value-Add: Complex layering, foam integration, proprietary self-locking mechanisms, and custom die-lines.
Material Science Meets Aesthetic Innovation
Full custom engineering for products with unique requirements or supply constraints.
Process: Rapid prototyping and sample creation to validate fit, strength, and machine-run speed before full production.
Focus: Utilizing custom board grades, specialized coatings, and high-definition print finishes to achieve specific performance and visual targets.
The Value-Add: Ask the Right Questions
Critical Supply Chain Consideration
A cheap quote is pointless if the box collapses in transit. We ensure your packaging is engineered for the rigors of your actual supply chain.
Our Value
Palletisation & Container Fit
We design box dimensions to maximize use of pallet and container space, reducing your overall freight costs.
Stacking Strength Assurance
We calculate the exact board grade required to withstand your specific storage time, stacking height, and humidity levels.
Courier Regulation Compliance
We ensure all designs meet strict courier and third-party logistics requirements to avoid rejection or penalties.