PFI manufactures heavy duty corrugated boxes in double wall and triple wall construction for large, heavy, and high value products. We build each box to your product weight, dimensions, and shipping method, and we size it to fit your pallets so every load ships stable and secure. From machinery parts and castings to bulk materials and export freight, PFI gives you a box strong enough for the job without paying for more board than you need.
Lower Than National Pricing
Delivery Across SoCal
Nationwide Shipping
CAD Design & Prototypes
Standard single wall boxes crush, bulge, and puncture under heavy loads. Double and triple wall construction adds layers of fluted board that raise stacking strength, puncture resistance, and rigidity. PFI provides:
We review your product, your stacking needs, and your freight route, then recommend the lightest construction that still protects your load. That keeps your cost per box down and your damage rate low.
Heavy duty boxes replace wood crates in many applications at a lower weight and cost. We build for products like these every day.
Motors, pumps, gearboxes, and assemblies that need rigid walls and strong bottoms to survive forklifts and long freight routes.
Dense, heavy parts that punch through lighter board. Triple wall construction and internal bracing keep them contained and separated.
Resins, fasteners, hardware, and components shipped in bulk bins and gaylord style boxes that sit on a pallet and hold hundreds of pounds.
Oversized products that need tall, stiff walls and corner protection to resist crushing when stacked in trailers and warehouses.
High value parts moving between suppliers and assembly plants, often in returnable or pallet mounted boxes.
Heavy loads that face multiple handoffs, long storage, and rough handling, where double or triple wall board can replace a wood crate.
Corrugated board strength is commonly rated by Edge Crush Test (ECT), which predicts stacking strength, or by burst strength (Mullen), which measures resistance to puncture and rough handling. The table shows typical ratings for heavy duty board.
Construction | Typical ECT | Typical burst | Best for |
Double wall | 42 to 82 ECT | 275 to 600 lb | Heavy products, palletized loads, stacked storage |
Triple wall | 90 to 112 ECT | 700 to 1,300 lb | Very heavy items, bulk bins, crate replacement |
Available grades shown by Mullen burst strength, apprximate ECT rating, and typical maximum gross load.
| Board Grade (Mullen) | Typical ECT | Typical burst |
| 900# | ECT-80 | 260 LB |
| 1100# | ECT-90 | 280 LB |
| 1300# | ECT-112 | 300 LB |
The most common style, efficient and economical
Outer flaps overlap fully for added top and bottom strength
A lid and base that slide together for tall or heavy items
Pallet sized containers for loose and bulk goods
Built around unusual shapes or loading needs
A heavy duty box performs best when it fits the pallet it ships on. Boxes that overhang the pallet edge lose much of their stacking strength, and boxes that underhang leave gaps that let loads shift. We size your boxes to your pallet footprint and stacking pattern so every load stays square and stable.
Boxes built to standard 48 x 40 pallets or your custom pallet size, with no overhang.
Boxes attached to wood or plastic pallets, or with integrated corrugated bases, for single unit handling by forklift.
Top caps, sleeves, and tie sheets that lock pallet loads together and protect edges.
Share as much of the following as you can, and we will recommend the right board, style, and size. If you do not know every answer, we will help you work it out.
Send your product specs, a drawing, or a sample, along with the details from our checklist. We review how the box will be loaded, stacked, and shipped.
We design the box, inserts, and pallet fit together, then build a prototype you test with your real product.
We produce your boxes in double or triple wall board to your approved spec, so every order matches the last.
We inspect every order, then deliver next day across Southern California and ship free nationwide through our distribution network.
We match board and style to your load, so you protect your product without overpaying for board.
We size every box to your pallet footprint for stable, secure loads.
We design and prototype your box at no cost, so you confirm performance before you commit.
Save 15% to 40% compared to national suppliers, with next day SoCal delivery and free nationwide shipping.
We provide local next day heavy duty box delivery across Southern California:
Multi-location and out of state businesses ship from our nationwide distribution centers in CA, TX, IL, PA, TN, and GA, so every facility receives the same heavy duty boxes.
Double wall boxes use two layers of fluted board between three liners, while triple wall boxes use three fluted layers between four liners. Triple wall gives you much higher stacking strength and puncture resistance for very heavy loads, while double wall handles most heavy products at a lower cost.
It depends on the board grade, box size, style, and how the box is stacked and handled. Double wall boxes commonly handle loads up to a few hundred pounds, and triple wall bulk bins can hold much more when sized to a pallet. Share your product weight and shipping details, and we will recommend the right construction.
ECT rated board is best when stacking strength matters, such as palletized loads and warehouse storage. Burst rated board is best when puncture resistance and rough handling are the bigger concern. We help you choose based on how your boxes ship.
In many cases, yes. Triple wall boxes weigh less, cost less, and are easier to recycle than wood crates. For extremely heavy or irregular items, we may recommend a crate or a hybrid solution with a pallet base.
Yes. We build boxes sized to your pallet and can supply pallet mounted boxes and bulk bins for single unit forklift handling.
Product weight and dimensions, how you ship and stack, storage conditions, pallet size, and expected volumes. See our checklist above, and send what you have.
Yes. We build every heavy duty box to your inside dimensions, from small dense parts boxes to full pallet sized bins.
