Single-Wall vs. Double-Wall Boxes: What Affects The Costs?

The difference between single-wall and double-wall boxes might seem obvious; their names do indeed tell us a lot. But questions about the costs of these boxes are not so simple. Finding the best box for you depends on several factors, and there is good news on the horizon: your final costs might surprise you. Read on to explore the relationship between cost, corrugation and quality.  

What Factors Affect Box Costs? 

How much do boxes cost? Fortunately, there is good news on the box-manufacturing front. The United States has ample natural resources for producing paper—both virgin and recycled materials—and for turning that paper into cardboard. The country has a good capacity for on-shore manufacturing. These factors help keep costs down for buyers in North America.  

There are three main factors in determining box pricing.  

• Material composition (single-walled vs. double-walled boxes): Few products are as clearly described by their names as single-wall and double-wall boxes. A double-wall box consists of, yes, two corrugated cardboard panels glued together, forming a thick wall of cardboard, resulting in a sturdy, heavy-duty box. It literally uses twice the material of a single-wall box (of the same size), and this naturally drives up the cost.  

• Order Quantity: Another top factor affecting box cost is your order quantity. Like many bulk products, boxes usually receive a significant discount when ordered in large quantities. This, of course, applies to both single-wall and double-wall boxes. The discount received on a bulk order might offset a large portion of the price difference between those two kinds of boxes.  
• Size: Bigger boxes use more material and therefore cost more. For both single-walled and double-walled boxes, within the standard sizing offered by manufacturers, larger sizes will cost more than smaller sizes.  
• Customization: Custom sizing for boxes will obviously affect costs, as well. While manufacturers and suppliers offer countless options for ordering boxes of all shapes and sizes, that customization comes with a price tag. A custom-ordered single-wall box could easily cost more than a standard-sized double-wall box.  

Are double-wall boxes worth the cost? 

As with most purchases, a thorough understanding of your application is helpful in deciding which box is best for you. Double-wall boxes provide exceptional performance, but you should only resort to them if your application justifies the cost. Typically, double-wall boxes are used when items are too heavy for a standard single-wall box or require extra protection.  

Double-wall boxes offer great protection for your contained items due to their exceptional puncture resistance. Not only does the box offer two walls of corrugated cardboard, but it also has extra layers of paper and glue holding those walls together. If your items need extra protection, a double-wall box is a great choice.  

Double-wall boxes are best for long-term storage, as well. Their sturdiness provides exceptional crush resistance. It’s possible a single-wall box would not be adequate for this application, especially if the objects within are heavy.  

Boxes are measured by their ECT and bursting strength. ECT is the Edge Crush Test. This test measures the stacking strength of corrugated boxes and they are given an ECT classification. Single-wall boxes typically have a thickness of 32 ECT and double-wall have a 48 ECT. Boxes are also measured by their bursting strength – the amount of force needed to break the wall of the box. They are classified by their # or lb. amount. Single-wall boxes have a maximum weight of 200lb and double-walled boxes have a maximum weight of 275lb. 

When making a choice between single-wall and double-wall boxes, it helps to ask the following questions.  

• What is the weight of your object or material that will be in the box? Check the maximum weight capacity for the single-wall box you are considering. If the weight exceeds the box capacity, you’ll have to use a double-wall box.  
• How will your boxes be stored and stacked? If you have heavy boxes that will be stacked on top of one another, a double-wall box may be worth the money.  
• What kind of stresses will your box be under during shipping? For most shipments, single-wall boxes are perfectly adequate. But if your objects require extra protection or you are anticipating especially rough treatment during shipping, a double-wall box may be a better value.  

What are the cost benefits of single-wall boxes?  

Single-wall boxes are your best option if your application is suited for them. If your contents are not too heavy or pointy, a single-wall box will most likely serve you well. If this is the case, there are many upsides. Single-wall boxes are usually cheaper than double-wall ones, and they make less of an environmental impact, as well. (It should be noted, however, that both single-wall and double-wall boxes are equally recyclable.)  

Are multi-depth boxes worth the money? 

Multi-depth boxes are a secret weapon in the packaging world. They might be your best value, as well. These boxes allow you to cut the sides down—usually in two-inch increments—in order to create a box of exactly the size you need. They come in both single-wall and double-wall thicknesses. Having a stack of multi-depth boxes provides flexibility and you won’t be stuck with a bunch of boxes that are either too big or too little for your needs.  

Multi-depth boxes are sometimes more expensive than single-wall boxes, but you could save money by only needing to stock one kind of box. And, as with most products, buying in bulk can create a discount. 

What are other cost factors to be aware of in box pricing? 

Every procurement decision is a multi-variable problem and brings up a lot of issues. Here are a few more that might shape your box-buying decision: 

• Brand name: The brand name of your boxes might send their price up or down. Sometimes that carries with it a guarantee of higher quality, but not always. Only pay more if you are certain the brand delivers on performance. 
• Printing: If you need your boxes printed with a logo or message, it will not only affect the price of the boxes but also, perhaps, the kind of box you should choose. Most boxes are made with an outer layer of printable cardboard, but be sure to confirm these details with your supplier.  
• Tape: Some boxes require more or higher-quality tape than others. For example, a double-wall box often requires a heavy-duty tape to hold it together under heavy loads. Be sure to factor any additional tape cost into your final decision and order accordingly.  

What are the top tips for saving money on boxes? 

• Focus on application: As always, it’s best to be mindful of your application and to use the most affordable option that gets the job done. If your shipping needs or storage needs are satisfied by single-wall boxes, then that is your best option. If your packages frequently vary by shape or size, multi-depth boxes might be the way to go. 
• Volume: Buy in bulk whenever possible. Often the discount you receive from a bulk order will offset a significant portion of a price difference between two boxes you are considering. You might be able to opt for a higher-quality or heavier-duty box if you buy in bulk. High-volume orders cut down on shipping expenses, too. Over time you will save serious money by ordering in bulk. 
• Packaging materials: A careful use of packaging materials—void fill, cushioning, and more—will let you get the most out of your boxes. You might be able to use a less substantial box if you package the contents in the right way. 

The Best Single-Wall and Double-Wall Box Values 

Working with a reliable supplier will help you find the right box for your application. Benchmark works with the top partners in the industry to ensure we have the most options and best prices. In addition, Benchmark also offers:  

• Price-match guarantee: Benchmark will match any price you find on single-wall or double-wall boxes. 
• Free delivery: Benchmark offers next-day local delivery for all orders of $150 or more.  
• Expertise: Our product experts can walk you through any questions you might have about boxes, tape, void fill or any packaging needs.  

Need to talk to someone about single-wall or double-wall boxes? Talk to one of our product experts.