Hollow Double-Wall Paper Cup Forming Solution

Hollow double-wall paper cups are specially designed for hot beverages. They consist of an inner cup and an outer sleeve, with an insulating air gap in between. This structure provides excellent heat resistance, structural strength, and branding flexibility, making them ideal for high-temperature drinks like coffee, hot milk tea, and chocolate beverages.

1. Application Scenarios

Hollow double-wall cups are widely used in:

✅ Hot beverage takeaway (coffee, milk tea, hot chocolate)

✅ High-end drink chains (dine-in and takeaway)

✅ Business meetings and office beverage service

✅ Self-service coffee machines

✅ Hot drink packaging in stations, airports, or trains

2. Capacity & Paper Configuration Recommendations

The most common hollow double-wall cup sizes range from 8oz to 16oz, with paper specifications optimized according to beverage temperature and branding needs:

✅ The outer sleeve does not require PE coating. Use food-grade printed, kraft, or embossed paper for enhanced texture and branding.
✅ Not recommended for cold drinks, as the outer layer may absorb moisture and lose structural integrity.

3. Structural Design Recommendations

✅ Structure: Inner cup formed by a paper cup machine; outer sleeve attached by a double-wall cup machine

✅ Insulation Principle: The air layer blocks heat conduction, offering excellent anti-scald performance

✅ Rim Diameter: Φ80–90mm, compatible with standard hot drink lids

✅ Customizable Shapes: Supports tapered or straight-sided designs for better visual distinction

4. Summary Recommendations

-✅Recommended Capacity: 8oz–16oz, covering mainstream hot drink sizes

-✅Recommended Structure: Single PE-coated inner cup + kraft or printed outer sleeve

-✅Paper Weight Guide: Inner cup ≥230gsm, outer sleeve ≥200gsm, adjusted based on size

-✅Core Advantages: Comfortable grip, excellent insulation, enhanced appearance—ideal for premium hot drink packaging

With the right combination of structure and paper materials, hollow double-wall cups offer superior heat protection, branding flexibility, and user experience, making them a preferred solution for modern hot beverage service.

Based on our years of experience in paper cup manufacturing, this solution offers professional recommendations on capacity selection, paper configuration, and structural design. We provide customized hollow cup solutions and can recommend suitable machine combinations to achieve efficient and high-quality production.