Skip to main content
Barton Jones Packaging Ltd
Industry solutions

Heavy-duty and large-format packaging

Oversized boxes, triple wall and pallet-stable packs for products that are too big, too heavy or too awkward for a standard stock box.

The problem

What usually goes wrong

Once a product goes past roughly a metre in any direction, the stock box market runs out. Buyers end up double-boxing, taping two boxes together, or paying for a timber crate they do not really need.

Large boxes also fail differently. The panels bow, the box loses stacking strength, and a pallet that looked stable in the warehouse arrives crushed on the bottom layer.

Weight makes it worse. A heavy product in an under-specified board turns a single knock into a write-off, plus a replacement, plus the carriage on both.

Typical pack

Packaging components we usually specify

  • Large format single-piece boxes in place of double-boxed workarounds
  • Double and triple wall transit boxes
  • Internal corrugated bracing, partitions and cap-and-tray constructions
  • Board or plastic edge protection under strapping
  • Standard, Euro and bespoke timber pallets sized to the box
  • Polypropylene, polyester, woven or steel strapping with the tooling to apply it
  • Bespoke timber crates where board alone is not enough

Materials

Relevant materials and board grades

  • Heavy-duty single wall with an uprated BC liner spec for 15kg to 25kg
  • BC double wall (approx. 7mm) for 25kg to 40kg and pallet stacking
  • Triple wall (approx. 10mm+) for 40kg and above, and near-crate protection
  • Heavyweight kraft liners where damp or long sea transit is a factor
  • Edge protectors and strapping matched to the load, not just the box

In-house

Our manufacturing and assembly capabilities

  • Large format boxes made on our own box-making machines, so the size is yours rather than the nearest stock option
  • No minimum on stock lines and bespoke runs from as little as one, so a run of 50 oversized boxes is worth quoting
  • Prototype first, drop-test with your real product, then commit to the run
  • Assembly and part-erection so your team is not folding large blanks on the shop floor
  • Pallet, crate and strapping supplied alongside the box as one specification

Stock holding

How we hold stock for you

  • Large packs eat racking. Buy the annual quantity, store it with us, call it off weekly
  • Scheduled call-off on our own vehicles, including full lorry loads where volume justifies it
  • One delivery combining oversized boxes with your everyday tape, film and void fill

Accreditations

Relevant accreditations for this sector

  • FSC C214479
  • BRCGS Storage & Distribution
  • Verified Carbon Standard
See our accreditations and request the literature

Real example

Replacing a double-boxed pack with one large box

A manufacturer shipping a 1.4m assembly was taping two stock boxes together, adding a timber base and strapping the result. It took two people around fifteen minutes per unit and still arrived damaged often enough to be a problem.

We made a single triple wall box to the finished dimensions, with an internal corrugated cradle and a bespoke pallet sized to the footprint.

Pack time came down to a few minutes for one person, the pallet stacks properly in the trailer, and the box cost less than the combined price of the two boxes, the timber and the labour it replaced.

Sector enquiry

Tell us the biggest thing you ship

Send the dimensions and weight of your most awkward product and we will spec the board grade, the box style and the pallet in one quote.

  • Product dimensions and weight
  • How it is handled: pallet, forklift, hand, or all three
  • Journey: UK pallet network, multi-drop, or export
  • How many you ship a month
Use the enquiry form01462 680888

Related sectors

Other industry solutions