Single Wall and Double Wall Corrugated Sheets
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3-Ply and 5-Ply Sheets in B, C and BC Flute
Single Wall and Double Wall Corrugated Sheets
Single-wall and double-wall corrugated sheets are the everyday converting board for layer pads, slip sheets, wraps and cartons. Choose B or C flute when you need a lighter 3-ply sheet with a usable print face; choose BC flute when you need 5-ply cushioning and higher stack strength. Sheets cut to pallet size, ship flat and are 100% recyclable. For thin, print-ready mailers and retail packs, see micro-flute sheets. For export and industrial loads, see triple-wall sheets.
Sheets. Pads. Cases. Built in 3-layer and 5-layer.
Applications of Single Wall and Double Wall Corrugated Sheets
• Single-wall cartons — RSC, FOL and die-cut shippers for consumer goods, e-commerce, food, electronics and spare parts. • Shelf-ready and high-graphics packs — E- and B-flute SW, often litho-laminated or digitally printed. • Double-wall export cases — appliances, furniture kits, automotive assemblies, bottled liquids, chemical pails. • Pallet layer pads — SW-HD or DW-STD sheets to separate stacked cartons, coils, bottles or parts and reduce crush. • Bottom / top sheets — protect pallet decks and cargo tops during stretch-wrap and container stuffing. • Dividers and fitted inserts — scored or die-cut SW/DW panels for components that do not yet need 7-layer board. • Stepping stone to triple wall — when DW ECT / caliper is insufficient, move to 7-layer BAC / AAC / AAA (see TDS-TW7). • Timber-crate alternative (DW-XHD) — lower tare than light plywood for many mid-mass loads; fully recyclable fiber, no ISPM-15.
Frequently Asked Questions About Single-Wall and Double-Wall Corrugated Sheets
Is “3-layer / 5-layer” the same as “single-wall / double-wall”?
Yes. Single-wall = 3-ply / 3-layer. Double-wall = 5-ply / 5-layer. “7-layer / triple-wall” is the next step up。
How is flute order written?
Outside to inside. BC means B-flute on the outside, C-flute on the inside. Mills sometimes reverse the code (BC vs CB). Confirm the outer flute when print quality or puncture resistance matters.
When is single-wall enough?
Consumer cartons, e-commerce, spare parts, food inner packs, light layer pads, and any job where cube, print and cost matter more than high stack load.
When should I step up to double-wall?
Export cases, appliances, bottled goods, automotive parts, reused pallet pads, and warehouse stacking. Typical BC flute: about 6.5–7.8 mm, 48–62 kN/m ECT, 500–650 psi burst.
When is even double-wall not enough?
Machinery, timber-crate replacement, very high stacks or high puncture. Move to 7-layer triple-wall (BAC / AAC / AAA).
Can I mix SW and DW in one pack?
Yes. A common pattern is a double-wall outer case with single-wall inner cartons or pads — or a DW pallet pad under SW shippers.
Which single-wall flute should I specify?
C — default shipping flute (balance of crush and cushion).
B — thinner, stiffer, better puncture; good for retail and die-cuts.
A — thickest SW cushioning (fragile / produce / light machinery).
E — print face, low cube (litho-lam, shelf-ready).
F — finest print / folding-carton substitute.
Which double-wall combination is most common?
BC (or CB). Use AC / AA when you need more cushion or caliper; EB / EC when you need a printable outer face on a thinner DW sheet.
Does outer flute change print quality?
Yes. E or B on the outside is smoother. A or C on the outside is more “washboard” and better for cushion than for fine graphics.
What do ECT and burst actually tell me?
ECT (TAPPI T 811 / ISO 3037) — edge crush; the main predictor of box stacking (BCT).
Burst / Mullen (TAPPI T 810 / ISO 2759) — resistance to rupture from internal pressure or blunt force.
Specify a number (e.g. ECT 26–34 kN/m or 48–62 kN/m). “Single-wall” or “double-wall” is not a strength grade.
What paper weights are typical?
Commercial export ranges:
SW total board: about 320–900 g/m² (economy → extra HD).
DW total board: about 550–1,550 g/m².
Example SW-STD: 150 / 110 / 150 g/m². Example DW-STD: 175 / 120 / 150 / 120 / 175 g/m².
Virgin kraft or testliner?
Virgin kraft outer: higher ring-crush, better appearance, higher price. Testliner / recycled inner: lower cost. Mix them if print and budget both matter.
What should I put on the purchase order?
Ply (2 / 3 / 5), flute letter plus locked height for G/H/N, liner grades, print face, sheet size, and the note “not B/C/A shipping flute; not 7-ply.”
Can these sheets be scored, slotted or printed?
Yes. Typical add-ons: score, slot, 1–4 colour print, anti-slip. E- and B-flute take print best. Heavy DW is usually one or two colours, not litho quality, unless the outer flute is E.
Is uncoated kraft water-resistant?
No. Strength drops sharply above about 85 % RH or after wetting. For damp lanes specify wet-strength, Cobb-treated or curtain-coated liners.
How should sheets be stored?
Flat, under cover, off the floor, 30–70 % RH. Do not store double-wall on-edge or crushed at the flute tips — stacking performance is lost before the sheet looks damaged. Ex-mill moisture is typically 7–9 %.
Do I order a sheet or a finished box?
Sheets / pads are blank or scored panels. Boxes are converted (RSC, FEFCO 0201, die-cut tray, etc.). BCT depends on style, size, humidity and closing method — test the finished pack, not only the board.
What must be on the PO?
Construction (SW-C or DW-BC), paper weights, liner type, performance target, size + flute direction, quantity / pack, converting/print add-ons, and Incoterms / port.
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