Custom Double Sided Mailer
Printing only the outside of a mailer wastes the single best surface you own. The exterior gets glanced at while a parcel is carried indoors. The interior is what the customer looks at while they open it, camera often already running. A double sided mailer uses both. We produce a lot of these at ZEE Packaging and the inside print is where the value genuinely sits.
The Inside Is Seen Longer
A double sided mailer puts your brand where attention actually is.
- The exterior is seen briefly and usually while being carried
- The interior is looked at directly during the unboxing moment
- Unboxing photographs and videos capture the open box, not the closed one
- Inside print costs a fraction of what outer print does
- It turns a plain shipping carton into a branded experience
- Customers share what they see, and they see the inside
Most brands who add a double sided mailer report more social posts almost immediately.
What To Put Inside
The interior needs different content to the exterior.
- A short message rather than a paragraph
- A QR code linking to a reorder page or a video
- A discount code for the next purchase
- Social handles positioned where they appear in photos
- A pattern or bold color, which photographs better than text
- Care or usage instructions where they genuinely help
- Roll end tuck front our most ordered double sided mailer
- Crash lock bottom assembles faster at a packing bench
- Book wrap style folds to the thickness of the contents
- Shipping box with a printed liner for larger orders
- Subscription format designed around a recurring reveal
- Padded interior version light protection with print
Sizes We Print Regular
Every double sided mailer is built to your product, though these run often:
- 6" x 4" x 2" for small items
- 8" x 6" x 3" for a standard order
- 10" x 8" x 4" for a mid size product
- 12" x 9" x 3" for apparel and flat goods
- 9" x 6" x 1" for a book wrap format
- 14" x 10" x 6" for multi item orders
Look at your order data rather than guessing. Most stores find three sizes cover nearly everything they ship.
Board And Print
- E flute corrugated for light single item orders
- B flute where parcels get stacked or the product has weight
- White corrugated inside for the brightest interior print
- Kraft corrugated with one color printed inside, a cheap effective route
- Litho laminated for full color on both faces
- Flexo printing for one or two colors at high volume
White inner liner is worth specifying. Print on kraft inside reads muted, which undercuts the effect you are paying for.
Materials That Make Sense
- Recycled corrugated, standard across these grades
- FSC certified board, certificate available on request
- Soy based ink through the whole run
- No lamination, so the mailer recycles curbside
- Paper tape and paper void fill rather than plastic
- Right sizing, which cuts both board and freight
How The Job Runs With Us
- 100 unit minimum, so a small brand can test the format
- Free 3D mockup and flat proof before anything prints
- Free dieline drawn by our own designer
- We hold your dieline so reorders skip setup entirely
- Urgent turnaround at 5 to 8 business days
- Free shipping worldwide, including to your fulfillment center
Frequently Asked Questions
Is inside print much more expensive?
Less than most people expect. One color inside adds very little per unit and delivers most of the branding value.
Will it print well on kraft?
Muted rather than bright. For vivid interior color we would specify a white inner liner instead.
Does it slow down packing?
Not at all. A crash lock bottom assembles in a second, and the print makes no difference to how it folds.
Can we change the inside seasonally?
Yes, and plenty of brands do. Keep the structure and reprint the interior for a campaign or a holiday.
How much does a two-sided mailer cost?
Rough estimate is $0.55 to $1.40 per unit for one color inside and out, $0.90 to $2.20 for full color and $1.60 to $3.60 for litho laminated at moderate quantity. Print coverage moves it. Shipping is included in our price. This is estimate only, so ask our team for a exact quote.
Should we add a QR code?
We would recommend it. It is the only way to measure whether the interior print actually drives anything.
Is it still recyclable?
Fully, provided you skip lamination and use paper tape. Ink coverage does not affect curbside recycling.
