Custom 5 Ply Corrugated Boxes from Prime Custom Packaging add a second flute layer for products that land in the mid-weight range most single-wall boxes can’t handle. Five layers stack liner, flute, liner, flute, liner, so the box resists crushing from multiple directions instead of just one. That extra structure matters most during stacking and multi-point handling, where a 3-ply box would start to give. Every order ships free across the United States, with a free dieline and zero minimum order quantity on any size we cut. Our in-house team builds each 5-ply box to your exact product dimensions rather than a generic template. Request a free quote and we’ll help confirm whether 5-ply is the right weight class for your product.
Some products just need more board between them and the forklift. Custom 5 Ply Corrugated Boxes from Prime Custom Packaging add a second flute layer for exactly that reason. Every order ships free across the United States. Zero minimum order quantity and a free dieline come standard from our in-house team. This line handles the mid-weight range most single-wall boxes cannot. Wholesale distributors order 5-ply boxes in bulk for mid-weight freight and storage.
A 5-ply board stacks liner, flute, liner, flute, liner in that order. Two separate flute mediums sit between three flat liners. Custom 5 Ply Corrugated Boxes use this doubled structure to resist crushing far better than single-wall board.
One flute layer cushions impact from a single direction well. Two flute layers, stacked and offset, resist compression from every side. That difference shows up most under stacked pallet weight in a warehouse.
Industry buyers know this board by two names. Ply count calls it 5-ply, while wall count calls it double-wall. Our Double-wall Corrugated Boxes line covers this identical construction under the wall-count term. Search either phrase and you land on the same board here.
| Industry | Common Product | Typical Weight | Why 5 Ply Fits |
| Electronics | Appliance parts, monitors | 60 to 150 lbs | Handles stacking without crushing components |
| Furniture | Flat-pack hardware, fixtures | 80 to 180 lbs | Resists puncture from sharp edges |
| Industrial goods | Machine parts, tools | 100 to 180 lbs | Survives repeated warehouse handling |
| Bulk retail | Multi-unit cases | 60 to 120 lbs | Stacks safely on pallets |
We build every box to your product’s exact dimensions, but common ranges cover most orders.
| Category | Typical Size | Suggested ECT |
| Mid-size shipping carton | 14 x 14 x 14 in (356 x 356 x 356 mm) | 44 ECT |
| Appliance or parts box | 20 x 16 x 12 in (508 x 406 x 305 mm) | 44 to 55 ECT |
| Bulk storage case | 22 x 18 x 16 in (559 x 457 x 406 mm) | 55 ECT |
Most 5-ply orders pair a B-flute with a C-flute for balanced strength and print quality. A double C-flute combination adds maximum cushioning for fragile industrial parts. We select the pairing based on your product weight, not a default setting. Products needing even more protection should review our Custom 7 Ply Corrugated Boxes line instead.
Offset printing suits larger production runs across a stable product lineup. Digital printing works better for shorter runs or seasonal SKU changes. We match CMYK for full-color artwork and PMS for a locked brand color. Any RGB file gets calibrated before it reaches press, regardless of board weight. Brands wanting heavier emphasis on branded graphics should also check our Custom Printed Corrugated Boxes line. It covers full-color branding across any wall type. Custom 5 Ply Corrugated Boxes still print cleanly despite the extra flute layer beneath the surface.
Water-based coating protects graphics without adding bulk to an already-thick board. Matte lamination suits retail-facing cartons that still need to look clean on a shelf. Most industrial 5-ply orders skip lamination entirely, prioritizing function over shelf presentation.
A slotted structure remains the most common format for this weight class. Our Custom Slotted boxes line covers standard shipping cartons in double-wall board. Products needing a lid separate from the base should see our Custom Telescopic boxes line. Die-cut trays and inserts are also available through our Custom Die Cut Corrugated Boxes line. Flat-pack goods that fold for storage fit our Custom Folder Boxes line, built in double-wall board on request. Brands shipping direct to consumers often prefer our Custom Corrugated Mailer Boxes line for a self-locking closure.
Palletized freight and export shipping usually exceed what double-wall board can safely carry. Our Triple-wall Corrugated Boxes line steps up to that weight class. Lighter shipments, by contrast, rarely need the extra cost of a second flute layer. Our Custom 3 Ply Corrugated Boxes line covers that lighter range at a lower price point. That lighter category is also sold under our Single-wall Corrugated Boxes line, using the wall-count name. Custom 5 Ply Corrugated Boxes sit squarely between those two extremes on strength and cost.
Zero minimum order quantity applies to every Custom 5 Ply Corrugated Boxes order. Standard orders ship in six to eight business days after proof approval. Rush production is available for time-sensitive launches. Shipping stays free across the United States, regardless of order size or weight class. Private-label manufacturers and retail-ready shipping teams both choose this balanced, sustainable structure.
Our in-house team builds your dieline at no charge, matched to your product weight and stacking needs. We recommend the right flute pairing and ECT rating before your order goes to press.
| Check | What We Verify | Why It Matters |
| Edge crush strength | Tested against the ECT rating you selected | Confirms the box holds its stacking weight |
| Flute bond integrity | Checked across both flute layers | Prevents delamination under repeated handling |
| Dieline accuracy | Within plus or minus 1/16 inch of approved dieline | Prevents loose flaps or a box that won’t seal |
We ship this line to every state at the same free-shipping rate. California and Texas manufacturers order the largest volume of double-wall parts boxes. New York and Illinois distributors favor this weight class for bulk retail cases. Los Angeles and Chicago electronics brands often request rush turnaround for a new product launch. Wherever your facility sits, the same zero-MOQ pricing applies.
Send us your product weight, dimensions, and stacking requirements. We will return a free dieline and quote within one business day. Zero minimum order quantity means you can start with a small test batch. Get a Free Quote Now. You can also email sales@primecustompackaging.com or call +1 (855) 611-8876 to speak with our team.
Order Now or email sales@primecustompackaging.com or call +1 (855) 611-8876 for a free quote today.
| Box Style | Custom 5 Ply Corrugated Boxes |
| Dimension (L + W + H) | All Custom Sizes & Shapes |
| Quantities | No Minimum Order Required |
| Paper Stock | 10pt to 28pt (60lb to 400lb) Eco-Friendly Kraft, E-flute Corrugated, Bux Board, Cardstock |
| Printing | No Printing, CMYK, CMYK + 1 PMS color, CMYK + 2 PMS colors |
| Finishing | Gloss Lamination, Matte Lamination, Gloss AQ, Gloss UV, Matte UV, Spot UV, Embossing, Foiling |
| Included Options | Die Cutting, Gluing, Scored, Perforation |
| Additional Options | Eco-Friendly, Recycled Boxes, Biodegradable |
| Proof | Flat View, 3D Mock-up, Physical Sampling (On request) |
| Turnaround | 4 – 8 Business Days, RUSH |
| Shipping | FLAT |
