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Size guide · chapter 02

Wall construction and strength

Wall count is the biggest single factor in what a bulk box can carry and how high it stacks. Here is what each construction is for, and how to read the box you already have.

2 → 5 wallECT vs MullenFlute profilesBMC decoded

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General guidance only. Check the rating on the box and with your supplier.
ConstructionWhere it is usually used
2-wall (double wall)Lighter loads, single trips, little or no stacking
3-wall (triple wall)The general-purpose bulk box; moderate loads, stacked a few high
4-wallDense material such as powders, resin and metal parts
5-wallThe heaviest loads, export and long storage

ECT versus Mullen

ECT — Edge Crush Test

  • Measures how much force the board takes on its edge.
  • Predicts stacking performance.
  • The usual specification for boxes that get stacked or stored.

Mullen — burst test

  • Measures resistance to a force pushed through the board face.
  • Predicts puncture and rough-handling tolerance.
  • Still required by some older specs and carrier rules.

The two tests measure different things and are not directly convertible. If you are replacing a certified box, match the test it was certified against.

How to read a Box Maker's Certificate

Most certified corrugated boxes carry a round stamp on a bottom flap. It holds most of the specification.

Board construction
Single, double or triple wall.
Test rating
Either a burst test (Mullen) or an edge crush test (ECT) value.
Size limit
The maximum combined outside dimensions the certificate covers.
Gross weight limit
The maximum weight of box plus contents.
Maker
Who made it. Useful when you need the same box again.

A photo of that stamp sent with your quote request saves a lot of back and forth.

Flute profiles

FluteRelative thicknessTypical role
AThickest common fluteCushioning and stacking; outer layers of multi-wall board
BThinnerPuncture resistance; inner layers
CBetween A and BThe most common shipping carton flute
EVery thinRetail and printed cartons, not bulk

Continue through the size guide

Send a photo of the stamp

One photo of the Box Maker's Certificate helps a partner supplier match your box.

Common questions

About wall construction and strength

Is triple wall the same as 3-wall?

Yes. Triple wall corrugated has three fluted layers between four liners.

Does more wall always mean better?

No. Extra board adds cost and weight and takes up space. Match the wall count to the load and stacking.