Ever wondered what makes your product box feel sturdy yet look sharp? The answer often lies in the types of duplex paper used. Whether it’s a glossy perfume package or a frozen food tray, duplex paper plays a bigger role than you might think.
In this post, you’ll learn what duplex paper is, why it’s widely used in packaging and printing, and what makes each type—like coated, uncoated, grey back, white back, and kraft—unique. We’ll also explore their features, applications, and how to pick the right one for your needs.
Duplex paper is a type of paperboard made from two distinct layers, or plies, pressed together. One side is usually smooth and printable, while the other can vary in texture or color. It’s known for being firm, durable, and ideal for folding, making it a go-to for packaging needs.
Quick Facts:
Two-ply structure for strength
Often one side coated
Suitable for high-quality printing and packaging
The process starts with recycled or virgin pulp, depending on quality needs. The base layer—often made from recycled grey paper—provides strength. The top layer is smoother and can be bleached or coated with clay or polymers to boost printability.
Basic Production Steps:
Pulp preparation from wood or recycled fiber
Formation of base and surface layers
Pressing and drying
Coating and finishing (if needed)
Cutting into sheets or rolls
Note: The coating may be single-sided or double-sided, based on intended use.
Different papers serve different roles. Here's how duplex paper stacks up against two common alternatives:
| Feature | Duplex Paper | Kraft Paper | Ivory Board |
|---|---|---|---|
| Surface Finish | Smooth (coated or uncoated) | Rough, natural brown | Ultra-smooth, premium white |
| Strength | Moderate to high | Very high | High |
| Printability | Excellent with coated surface | Low (inks absorb quickly) | Excellent |
| Common Uses | Boxes, cartons, book covers | Bags, wrappers, heavy-duty use | Luxury packaging, menus |
| Cost Range | Affordable | Affordable | Expensive |
Key Points:
Duplex paper gives you print quality without the high cost of ivory board.
Kraft paper is stronger but less refined for visuals.
Duplex paper comes in two basic surface types: coated and uncoated. The coated version has a smooth layer—usually made of clay or polymer—applied to one or both sides. This improves the surface’s ability to hold ink, making it ideal for vibrant prints. Uncoated versions feel more natural and are better for low-cost or industrial uses.
| Feature | Coated Duplex Paper | Uncoated Duplex Paper |
|---|---|---|
| Surface Texture | Smooth, glossy | Rougher, matte |
| Print Quality | High—great for images and color | Moderate—best for basic text |
| Typical Use Cases | Packaging boxes, labels | Corrugated liners, industrial packs |
| Ink Absorption | Low—ink stays sharp | High—may cause some ink spread |
GSM stands for grams per square meter. It tells us how thick and heavy the paper is. Duplex paper typically ranges from 200 to 500 GSM. Higher GSM means thicker, more rigid sheets. For folding boxes or heavy-duty packaging, businesses usually go for 300 GSM or more.
| GSM Range | Description | Best Uses |
|---|---|---|
| 200–250 | Light and flexible | Inner cartons, booklets |
| 300–350 | Balanced weight and strength | Cosmetic and pharma packaging |
| 400–500 | Thick and highly rigid | Food trays, electronic goods boxes |
Duplex paper doesn’t easily bend or tear. Its two-layer design creates a sturdy structure, making it reliable for product protection and handling during transport.
The coated side—especially if glossy—feels smooth and looks professional. This finish helps highlight printed graphics and keeps colors sharp and consistent.
It works well with offset, inkjet, and laser printing. The coated side holds ink evenly, reducing smudges and enhancing detail. That’s why many brands choose it for bold packaging designs.
Because it's semi-rigid, it won’t crack easily when folded. This is essential for boxes or cartons that need sharp edges and clean folds to hold shape.
Wax-coated or clay-coated versions resist water well. That’s why duplex paper is often used for frozen foods or items stored in humid environments.
Quick Highlights:
Rigid enough to protect products inside
Smooth for better visuals
Reliable even under folding stress
Some types resist moisture for better durability
Coated duplex paper has a smooth, polished surface thanks to a clay or polymer layer. It enhances color sharpness and makes designs pop. You’ll find both single-side and double-side coated options, depending on print needs.
| Coating Type | Description | Typical Use Cases |
|---|---|---|
| One-side coated | Glossy or smooth on one side, rough on back | Product boxes, outer cartons |
| Two-side coated | Smooth on both surfaces | Labels, luxury packaging, brochures |
Perfect for items that require bold visuals like food, clothing, and tech accessories
Supports high-resolution printing and vibrant ink retention
Uncoated duplex paper skips the glossy finish and keeps a more natural texture. It feels raw, slightly rough, and absorbs ink more quickly. This makes it an economical choice for basic printing needs where vibrant visuals aren't a priority. It's often used in book covers, inner box linings, and packaging where aesthetics are less critical.
Grey back duplex paper features a white or off-white print surface and a grey bottom layer—usually made from recycled pulp. It’s strong and widely used for industrial and secondary packaging.
| Feature | Advantage |
|---|---|
| Recycled content | Lower material cost |
| Grey reverse side | Ideal when back won’t be seen |
| High rigidity | Withstands stacking and heavy loads |
Pros: Affordable, rigid, and easy to print on one side
Cons: Less appealing appearance on the reverse side
White back duplex paper provides a clean white surface on both sides. It’s perfect for premium packaging where appearance matters. The smoothness of both faces supports sharp printing, making it a preferred choice for electronics, cosmetic boxes, and upscale product packaging. It’s also great when both sides of the box are visible to the end customer.
Kraft duplex paper combines the stiffness of a duplex board with a kraft paper backing. The front layer is usually coated or smooth for printing, while the back has a raw, brown kraft finish. This style is popular for giving a rustic or handmade look—great for food trays, craft items, or anything needing a more natural aesthetic.
FBB is engineered for folding and creasing. It’s made up of multiple layers, with a bleached top sheet and mechanical pulp core. That combo gives it both strength and style.
| Key Attributes | Value |
|---|---|
| Lightweight but stiff | Maintains shape while being easy to fold |
| Clean white surface | Perfect for brand-focused packaging |
Used in pharma packaging, cosmetics boxes, and retail cartons
Performs well with embossing, foil stamping, and complex die cuts
This type includes a thin wax layer over the surface to block out moisture. It's designed to survive humid storage or freezer environments.
Great for frozen food, dairy, or seafood packaging
Prevents paper from absorbing liquids during storage
Smooth enough to print on while protecting the contents
Use Tip: Always choose wax-coated variants when water resistance is key to product safety.
Printing Needs
Consider the print method you'll be using. Coated duplex papers are ideal for high-quality prints with vibrant colors, while uncoated papers are more suited for simpler, less intricate designs.
Budget
Duplex paper comes in different price ranges. Higher-quality options, like Folding Boxboard (FBB), tend to be pricier but offer better durability and print quality. Make sure your paper choice aligns with your budget while meeting your needs.
Product Type
The type of product you're packaging can determine the paper choice. For heavier products, opt for papers with higher GSM for better strength. Lighter products can often use a lower GSM paper without compromising on quality.
Box Strength and Rigidity
If your packaging needs to withstand rough handling or stacking, focus on a paper with greater rigidity. Duplex paper with a higher GSM will provide more durability and reduce the chance of box damage.
Surface Appeal
The surface texture of the duplex paper influences the look and feel of your product. A smooth, coated finish provides a polished, professional appearance, while an uncoated texture offers a more natural, organic look.
In food and beverage packaging, coated duplex paper provides durability and moisture resistance, while FBB is ideal for pharmaceuticals due to its strength and moisture resistance. Apparel packaging benefits from smooth, coated duplex for a premium look, while uncoated paper gives stationery a rustic, textured finish suitable for cards and boxes.
Understanding how duplex paper compares to other common paperboard types is essential when selecting the right material for your packaging needs. Here’s how duplex paper stacks up against kraft paper, ivory board, and corrugated board.
Durability
Duplex paper is thicker and stronger than kraft paper, making it more suitable for premium packaging. Kraft paper, while strong, is less rigid and offers less protection for delicate products.
Appearance
Duplex paper provides a smoother, more polished surface ideal for printing high-quality graphics. Kraft paper has a more natural, rustic appearance, which is good for eco-friendly or simple packaging needs.
Strength
Duplex paper is generally thicker than ivory board, which means it offers better box strength. Ivory board is often used for lighter applications where smoothness and brightness are key, like high-end stationery.
Surface Quality
Ivory board typically has a smoother and brighter surface than duplex paper, making it ideal for high-resolution prints. Duplex paper’s slightly textured finish gives it a unique look, though it may not be as glossy as ivory board.
Protection
Corrugated board provides excellent protection for fragile items due to its layered structure, making it better suited for heavy-duty shipping. Duplex paper, while strong, doesn’t provide the same shock absorption as corrugated board.
Flexibility
Duplex paper is more flexible than corrugated board, which makes it easier to fold and shape for various packaging forms. Corrugated board’s rigidity is advantageous for larger, heavier boxes.
| Paper Type | Best For | Strength & Durability | Print Quality | Flexibility |
|---|---|---|---|---|
| Duplex Paper | Premium packaging, cosmetics, food | High | Good, slightly textured | Moderate |
| Kraft Paper | Eco-friendly packaging, shipping | Moderate | Low | High |
| Ivory Board | Luxury packaging, stationery, cards | Moderate | Excellent (smooth surface) | Low |
| Corrugated Board | Shipping, heavy-duty packaging | Very High | Low | Low |
Duplex paper offers several benefits, but it's also important to be aware of some potential drawbacks.
High Printability
Duplex paper offers great print quality. Its smooth, coated surface ensures sharp, vibrant colors and fine details, making it ideal for packaging that requires high-quality graphics.
Strength and Durability
With its sturdy construction, duplex paper provides excellent protection for products. It’s strong enough to handle the rigors of packaging, stacking, and transportation.
Affordable Pricing
Compared to other premium paperboard types, duplex paper is relatively cost-effective. It provides a balance of quality and affordability, making it suitable for a variety of applications.
Wide GSM Options
Duplex paper comes in a range of GSM (grams per square meter) options, offering flexibility depending on the strength and thickness required for your packaging.
Lower Ink Adhesion
Due to its smooth surface, duplex paper can sometimes have lower ink adhesion, especially for certain printing methods. To overcome this, lamination or a protective film might be needed for better print durability.
Less Flexible Than Some Other Boards
While duplex paper offers strength, it is less flexible than other types, like kraft paper. This can make it more challenging to fold or shape, especially for packaging with intricate designs.
Duplex paper is versatile, finding applications in various industries due to its strength, durability, and printability.
Boxes, Trays, Wraps
Duplex paper is commonly used for packaging products like boxes, trays, and wraps, offering strength and durability for secure protection.
Labels, Brochures, Book Covers
It’s widely used for printing high-quality labels, brochures, and book covers, providing a smooth surface for vibrant colors and designs.
Notebooks, Folders
Duplex paper is ideal for notebooks and folders. It provides the necessary rigidity for maintaining shape while supporting quality printing.
Toys, Electronics, Cosmetics
This paper is often used for packaging consumer goods like toys, electronics, and cosmetics, ensuring protection and a polished presentation.
Duplex paper is essential for packaging and printing due to its strength, versatility, and affordability. With options like coated, uncoated, and grey back duplex paper, businesses can select the right type based on product needs and aesthetics, ensuring optimal performance.
For businesses, choosing the right duplex paper involves balancing cost and functionality. Evaluate your product's requirements, whether for food packaging or luxury items, to make an informed decision that suits both budget and quality needs.
Grey back duplex paper has a grey-colored reverse side, offering cost savings. White back duplex paper has a clean, white surface on both sides, providing a more premium appearance.
Yes, duplex paper is often used for food packaging, especially when coated for moisture resistance. It helps maintain product integrity and provides excellent printability.
For packaging boxes, a GSM range of 250-350 is typically ideal. Higher GSM provides more strength and durability, especially for heavier items.
