Custom Printed Cups

Double Wall Coffee Cups

Custom double Wall Coffee Cups produced to your size and substrate, with printing and finishing handled in one run.

Minimum order
100 units
Production
3–5 business days
Construction
paper cup
Delivery
US, UK, Canada, Australia

No obligation

Quote this by the case

Name, email, phone and what you are packing and the volumes you run. Attach artwork if you have it. We reply with a specification and a written price, usually within one business day.

The more detail you give, the more accurate the quote.

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PDF, AI, EPS, SVG, PNG, JPG, WEBP or ZIP. Up to 5 files, 10 MB each.

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    What double wall coffee cups have to cope with

    Double Wall Coffee Cups hold hot drinks where the cup has to be comfortable in the hand without a second component. That is the starting point for the specification, because double-wall cups are wider externally than single-wall at the same volume. Lids are matched to the rim, and rims differ.

    In service they are used for coffee service where speed at the counter matters and handling a sleeve slows things down.

    Where double wall coffee cups are actually used

    Double Wall Coffee Cups are specified for coffee service where speed at the counter matters and handling a sleeve slows things down. Double-wall cups are wider externally than single-wall at the same volume. Lids are matched to the rim, and rims differ.

    • Coffee service where speed at the counter matters and handling a sleeve slows things down
    • Coffee shops and cafés
    • Quick-service restaurants
    • Events and catering

    The substrate for double wall coffee cups

    Double-wall board construction with a food-contact lining on the inner wall only.

    The options we would consider for this format are below; double-wall cups are wider externally than single-wall at the same volume. Lids are matched to the rim, and rims differ.

    • Single-wall PE-lined paperboard
    • Double-wall paperboard
    • PLA-lined compostable board
    • Ripple-wall board

    Printing double wall coffee cups

    The outer wall is a separate piece, which gives a cleaner print surface than a single-wall cup.

    Offset lithography, Flexography, Digital press are all available for this format. Run length usually decides which is cheapest: digital removes the plate cost on short quantities, offset and flexo overtake it at volume.

    Finishing double wall coffee cups

    The outer wall is a separate piece, which gives a cleaner print surface than a single-wall cup.

    Finishes are costed one at a time because each is a separate operation — that way you can see which one is carrying the price.

    • Matte outer
    • Gloss outer
    • Uncoated kraft outer
    • Soft-touch outer

    Sizing double wall coffee cups

    Typically 8oz, 12oz and 16oz, running slightly larger externally than single-wall at the same volume.

    Send the contents rather than a box size. A switch from single to double-wall is made without checking lid compatibility, stranding existing lid stock.

    What moves the price

    Four things drive a quote more than anything else: the quantity, the print route, the board grade and the number of finishing passes. Dimensions matter too, but usually through how efficiently the shape nests on the press sheet.

    Prices start from $0.30 per piece for large-volume orders. If a cheaper route exists we say so at quoting rather than after the invoice.

    Holding double wall coffee cups before service

    Lids from a single-wall range do not fit, because the outer diameter differs even at the same capacity.

    Paperboard also absorbs moisture from the air until it equalises with its surroundings. If stock sits more than about six weeks in unconditioned space, a moisture-resistant coating is worth its small premium.

    Getting artwork press-ready

    Cup artwork is built on a fan-shaped dieline. Keep type at least 6 mm from the top rim and bottom curl, and expect slight distortion at the seam.

    Supply a print-ready PDF or vector file with fonts outlined and images at 300 dpi. Our prepress team checks every file before a proof is issued. The check that catches most files is type sitting too close to a crease, which is easier to move at layout than at proof.

    From enquiry to delivery

    Start with dimensions and quantity. If you already run something similar, a physical sample tells us more in a minute than a specification does in a page.

    A dieline template follows, sized to your product. Prepress checks your artwork against it and issues a proof; nothing runs until you sign that off.

    Checking it before you commit

    A plain structural sample is the cheapest way to find a fit problem — far cheaper than finding it across a full run.

    Sample costs are normally credited against the production order.

    Reference

    Double Wall Coffee Cups at a specification level

    ProductDouble Wall Coffee Cups
    CategoryCustom Printed Cups
    ConstructionPaper cup
    LiningPE or PLA liquid barrier
    RimRolled rim, lid-compatible
    WallSingle, double or ripple wall
    MaterialsSingle-wall PE-lined paperboard, Double-wall paperboard, PLA-lined compostable board, Ripple-wall board
    PrintingOffset lithography, Flexography, Digital press
    FinishesMatte outer, Gloss outer, Uncoated kraft outer, Soft-touch outer
    Minimum orderMinimum order is 100 units on any format, and unit cost falls sharply as the quantity rises.
    Lead time3 to 5 business days after artwork approval
    ShippingAcross the US, UK, Canada and Australia

    Specification builder

    Specify Double Wall Coffee Cups in under a minute

    Set what you know, leave the rest. Everything here travels with your request, so nothing gets retyped.

    • 100-unit minimum
    • 3–5 day production
    • Free dieline
    • No obligation
    Approximation only — proportions, colour family and finish character. Not a colour proof, and the panel shown is a placeholder, not your artwork.
    Packaging type
    Box style
    Quantity
    Colour
    Material
    Printing
    Finish

    Drop files or browse

    Up to 5 files, 10 MB each.

      Prices start from $0.30 per piece for large-volume orders. Final pricing depends on size, material, printing, finishes, and quantity.

      What you get

      What you get with this format

      The dimensions that matter

      Typically 8oz, 12oz and 16oz, running slightly larger externally than single-wall at the same volume.

      What goes wrong in service

      Lids from a single-wall range do not fit, because the outer diameter differs even at the same capacity.

      Where it has to work

      Specified for coffee service where speed at the counter matters and handling a sleeve slows things down.

      What decides the job

      Double-wall cups are wider externally than single-wall at the same volume. Lids are matched to the rim, and rims differ.

      This format sits in our custom printed cups range, alongside 21 other made-to-order formats.

      Answers

      Running double wall coffee cups: common questions

      Specification, minimums and lead times for double wall coffee cups.

      Will my existing lids fit double-wall cups?

      Not necessarily. Double-wall cups are wider externally at the same volume, and lids are sized to the rim. Check the rim diameter before switching, or you will strand your lid stock.

      Are these food-contact compliant?

      We specify food-contact compliant boards and inks where the pack touches food directly. Tell us whether contact is direct or through a liner for double wall coffee cups, because it changes which stocks are available to you.

      How do you stop grease showing through?

      A grease-resistant coating or a greaseproof liner. Untreated board will always strike through eventually with hot, oily food — that is a property of the material rather than a quality fault, and it is inexpensive to design out.

      Are these suitable for hot and cold drinks?

      The wall construction and the lining differ between the two. A cup specified for hot service will sweat with a cold drink, and a cold cup will not insulate. Tell us which service you need, or both if you want a single stock item.

      What file format should I send artwork in?

      A print-ready PDF or a vector file, with fonts outlined and any raster images at 300 dpi at final size. We supply the dieline to design onto, and prepress checks bleed, safe area and crease clearance before issuing a proof. The dieline we supply carries the crease positions, so keeping type clear of a crease is easier to solve at layout than at proof.

      What is the minimum order for double wall coffee cups?

      A flat 100 units on any format. Most paper cups in this range are quoted from 100 units upward because unit cost falls sharply above that, but the minimum exists so you can validate a structure first.

      How long do double wall coffee cups take to produce?

      3 to 5 business days after artwork approval, plus freight. Paper cup runs with applied finishes can take longer because each finish is a separate pass, and we confirm a firm date in writing with the quote.

      What do double wall coffee cups cost?

      Prices start from $0.30 per piece for large-volume orders. For this format the biggest levers are quantity, print route, board grade and how many finishing passes are involved. We quote each element separately so you can see where the money is going. Finishing passes are the lever buyers most often underestimate: each one is a separate run through the line.

      Can I see a sample first?

      Yes. We can send a plain unprinted sample so you can check the fit and structure, or a printed prototype for colour and finish. Sample costs are normally credited against the production order. Worth running a few through your actual line rather than checking them by hand: fill speed and hot contents find fit problems that a desk check does not.

      Can you match packaging we already use?

      Send the current specification or a physical sample and we will quote to match it rather than proposing an alternative you would then have to re-approve internally. Tell us the coating on the pack you are matching too. Grease and moisture resistance are not visible in a sample and they change which stocks we can quote.

      Where do you deliver?

      All 50 US states, the United Kingdom, Canada and Australia, on the same timeline everywhere: 3 to 5 business days of production after artwork approval, then 5 to 7 business days in transit. Every run is made to order and shipped directly to your address rather than pulled from stock, so you receive current production rather than whatever has been sitting in a warehouse. Freight is costed separately by weight, volume and destination. This format nests or lies flat, so a large quantity takes up far less freight volume than the finished pack suggests.

      Can I order double wall coffee cups in a custom size?

      Every run is cut to your dimensions — there are no stock sizes here. Send the product measurements rather than a box size and we will build the paper cup around them, then send a dieline template you can design onto.

      Next step

      Get a price for Double Wall Coffee Cups

      Send the fill size and the volumes you run. We reply with a full specification and a written price, usually within one business day.