Heavy duty packaging
Cardboard pallet boxes made to measure
Double and triple wall pallet boxes manufactured in our Letchworth factory, sized to your pallet and your load.
Pallet boxes built around the load
A pallet box sits squarely on the pallet footprint, so the load travels as one unit and can be stacked without crushing the box below. We make corrugated pallet boxes for single heavy assemblies, bulk fills of smaller parts and production line runs, using large-format machinery that handles board up to 2.8 metres wide.
- 1200 x 1000 mm (standard UK pallet)
- 1200 x 800 mm (Euro pallet)
- Made to measure, any height to suit the load
- Samples, one-offs and short runs
Any height
Cut to your product, from a shallow sleeve to a tall multi-layer container.
Double or triple wall
Grade chosen around load weight, stack height and handling.
Reinforced options
Reinforced edges, stitched construction, matched lids and bases.
Our own fleet
Delivered on our own vehicles locally, national supply available.
Choosing the board grade
Triple wall is the usual answer for heavy, tall stacked loads and export. For some loads a strong double wall grade does the job with less board. Our AC1000 double wall vs triple wall article walks through an illustrative pallet box comparison. See also our heavy duty cardboard boxes and made to measure boxes.
Pallet box FAQs
- What sizes of pallet box do you make?
- We make pallet boxes to suit the load rather than from a fixed stock range. The most common footprints are 1200 x 1000 mm for a standard UK pallet and 1200 x 800 mm for a Euro pallet, with the height cut to order around your product.
- Should I use double wall or triple wall?
- It depends on the load weight, the stack height and how the box is handled. Triple wall is the usual choice for heavy pallet boxes because it resists compression when stacked, but a well-specified double wall grade such as AC1000 can be enough for some loads. We specify the grade around your actual product and transit conditions.
- Can pallet boxes replace timber crates for export?
- Often, yes. Heavy-duty triple wall construction is lighter to freight, quicker to pack and recyclable through a single stream. We will tell you where timber is still the sensible answer.
- Do I have to order a large quantity?
- No. Samples, one-offs and short runs are commercially viable on our case-making equipment, with no cutting forme needed on many styles. We can also hold stock in our Letchworth warehouses for call-off.
Send us your pallet and load
Tell us the pallet size, load weight, stack height and how it travels. We will recommend the grade and construction.