Mailer Boxes
Built to Ship. Designed to Unbox.
Custom mailer boxes tailored to your vision. Protect your products with crush-resistant corrugated cardboard, fully customizable dimensions, and vibrant inside-out printing finishes.
Technical Specifications
Materials
Printing
Finishes
Popular Formats
Roll End Tuck Top (RETT)
Standard self-locking box with front-tucking lid, ideal for subscription boxes and general e-commerce.
Roll End Tuck Front (RETF)
Features side cherry locks for extra security and dust protection, perfect for premium retail items.
Peel and Seal Mailer (PSM)
Built-in adhesive and tear-strip for fast assembly, tamper resistance, and high-volume fulfillment.
Literature Mailer (LITM)
Flat, front-tuck mailer with minimal depth, built for shipping books, documents, and apparel.
C-Series Mailer (CSM)
Classic oyster-style box with a hinged lid that opens like a chest, providing a dramatic full-view presentation for subscription kits.
Variable Depth Mailer (VDM)
Engineered with multiple pre-scored crease lines along the walls, allowing you to easily adjust the box height to fit different product sizes.
Heavy-Duty Mailer (HDM)
Engineered with double-wall fluting for maximum crush resistance and bursting strength, ideal for heavy electronics, tools, and industrial parts.
Custom-Insert Mailer (CIM)
Pairs a secure roll-end mailer with a precision die-cut cardboard or foam matrix to lock multiple products firmly in place for a flawless reveal.
Form meets Function.
E-Flute Standard Kraft Corrugated
Durable 1.5mm (32 ECT) natural brown board offering a rustic look for simple, bold prints.
E-Flute Premium Coated White
Smooth 1.5mm clay-coated (Kemi) board with a brilliant white base for vivid CMYK color output.
B-Flute Standard White Corrugated
Thicker 3.0mm board providing enhanced structural support for heavier retail bundles and tech.
Water-Based Coated Compostable
Plastic-free aqueous (AQ) sealed board that remains 100% recyclable and fully compostable.
Popular Features
Die-Cut Cardboard Inserts
Tailored structural inserts to lock fragile products in place and prevent transit damage.
Custom Tissue Paper Inserts
Branded internal wrapping that elevates the unboxing experience and protects against shifting.
Custom Brand Stickers
Branded adhesive seals that secure closures, provide tamper evidence, and reinforce your logo.
Hot Foil Stamping
Metallic accents that reflect light to give logos and key brand elements a luxury finish.
Print & Finish
Digital Printing
Full CMYK print without expensive setup plates, perfect for short runs and fast turnarounds.
Offset Lithography
High-res litho-lamination delivering photo-realistic imagery for premium, high-volume orders.
Flexography
High-speed direct printing with flexible plates, ideal for cost-effective bulk runs and simple artwork.
Screen Printing
Dense, vibrant ink layers forced through mesh screens for high-contrast prints on raw kraft.
White Ink Printing
Opaque white under-layer that keeps CMYK colors bright and vivid on natural brown kraft.
Pantone Spot Color Matching
Exact pre-mixed PMS inks ensuring flawless brand color consistency across every production run.
Double-Sided Printing
Full interior and exterior printing to create an immersive, high-impact unboxing experience.
Eco-Friendly Soy & Plant Inks
Sustainable, plant-based inks that deliver rich colors while keeping boxes fully recyclable.
Mailer Boxes FAQ
What is the minimum order quantity (MOQ)?
Our MOQ is 500 units for custom printed mailer boxes, keeping your unit costs low and production efficient.
How much do custom mailer boxes cost?
Pricing depends on size, material, and print finish. Ordering at our 500-unit MOQ yields significantly lower per-box rates.
What sizes do corrugated mailer boxes come in?
We produce fully custom dimensions tailored to your product, alongside standard sizes for apparel, cosmetics, and subscription sets.
Do mailer boxes need packing tape?
Most self-locking styles (like RETT and RETF) require no tape. For high-volume fulfillment, Peel & Seal mailers offer built-in adhesive strips.
What is the difference between a mailer box and a shipping box?
Mailers fold into self-locking structures ideal for branded unboxing experiences. Shipping boxes (RSC) require tape and are built for heavy bulk transit.
Are custom mailer boxes eco-friendly and recyclable?
Yes, our corrugated mailers are 100% recyclable. We offer post-consumer recycled kraft, FSC-certified board, and plant-based soy inks.
What is the difference between E-Flute and B-Flute?
E-Flute (1.5mm) is sleek and ideal for retail mailers. B-Flute (3.0mm) is thicker, offering enhanced puncture protection for heavier items.
How long does production take for custom mailer boxes?
Standard production runs 10–12 business days after final artwork approval. Rush production options are available for tight deadlines.
Ready to Build Your Custom Pouch?
Full circle packaging solutions in-house! We'll get you off the starting line and see you through the finish!