Create Your Own Mailing Boxes & Packaging

Custom Mailer Boxes & Mailer Packaging

Ecommerce changed what a box has to do. It used to just get product from A to B. Now the same box has to survive a courier, look good on camera, and give somebody a reason to film themselves opening it. That is a lot to ask from corrugated board, but a well built mailer handle all three.

We print a huge volume of mailer packaging at ZEE Packaging, and after enough runs you learn what actually matter and what is just noise.

Why The Mailer Box Took Over

A mailer box is a one piece corrugated design, usually roll end tuck front or roll end tuck top. It ship to you flat, fold up in about five second with no tape, and the double side wall give your product real protection.

Compare that to a folding carton in a poly bag and it is not close. Mailer packaging protect corners, resist crushing, and give you a printable surface on the inside too.

• No tape needed, the front tuck hold it shut
• Ships and stores flat, saves warehouse space
• Double wall on the side, where damage usually happen
• Inside print surface, free real estate for your brand
• Fits letterbox and parcel network both

Styles We Build

• Roll end tuck front (RETF) the classic mailer box, our best seller
• Roll end tuck top (RETT) top loading, good for flat item
• Roll end front lock (REFL) locking tab, more secure mailer packaging
• Mailer with tear strip easy open, popular for subscription
• Full flap mailer extra flap for double protection
• Literature mailer shallow depth, book and print item
• Shipping box with insert mailer packaging with die cut cradle inside

Sizes That Actually Get Ordered

There is no true standard because every product is different, but these size come up again and again in our mailer box work:

• 6" x 4" x 2" for small accessory, jewelry, cosmetic
• 8" x 6" x 2" for apparel and flat item
• 9" x 6" x 3" for candle, mug, small kit
• 10" x 8" x 3" for subscription mailer packaging
• 12" x 9" x 4" for hoodie and multi item order
• 14" x 10" x 4" for bulkier retail mailer
• 16" x 12" x 6" for large kit and gift set

Send us your product dimension and we build the dieline around it. Right sizing your mailer box is genuinely one of the easiest way to cut your shipping bill.

Board And Flute, The Part People Skip

This is where mailer packaging succeed or fail, and most brand dont think about it enough.

• E flute (1.5mm) most common for mailer box, thin, prints sharp, light product
• B flute (3mm) stronger, better crush resistance, our pick for heavier item
• F flute (0.8mm) very thin, premium print, light weight
• EB double wall serious protection for fragile or heavy mailer packaging
• Kraft liner natural brown, cheap, very on trend
• White top kraft white outside, brown inside, good print surface
• Fully bleached white cleanest print for premium mailer

Honest advice, if your product is over two pound, go B flute. E flute look fine until a courier stack a pallet on it.

Print Options

Corrugated print differently than flat carton, so expectation matter.

• Digital print small run mailer box, full color, no plate cost, photo quality
• Flexo print high volume mailer packaging, one to three color, cost effective
• Litho lamination printed sheet mounted to board, best quality, higher minimum

For one or two color kraft mailer box, flexo is by far the cheapest route. For full color artwork with gradient, digital or litho lam.

Making Unboxing Worth Filming

The inside of a mailer is the most under used space in ecommerce.

• Print the interior, pattern, message, brand story
• Tissue paper, printed or plain
• Belly band and sticker seal
• Thank you card and discount insert
• Die cut foam or paperboard insert to hold product still
• Tear strip so nobody need scissor
• Matte lamination outside, though it add cost

Sustainable Mailer Packaging

• Recycled kraft mailer box, no lamination
• FSC certified corrugated, certificate on request
• Soy and water based ink
• Paper tape and paper void fill
• Right sized mailer packaging, less air shipped, lower carbon and lower freight

Uncoated kraft mailer box go straight in curbside recycling, which is a real selling point now.

Working With Us

• 100 unit minimum on every mailer design
• Free 3D mockup and flat proof
• Free dieline from our inhouse team
• Urgent turnaround 5 to 8 business day
• Free shipping worldwide

Frequently Asked Questions

How much do mailer boxes cost per unit?
Rough estimate is $0.60 to $7.40 per unit at moderate quantity, depending on size, flute and print coverage. Inside printing and lamination push it up. Shipping is included in our price. This is estimate only, ask our team for a exact quote.

E flute or B flute for my product?
Under two pound, E flute is fine and prints better. Over that, B flute. If it is fragile or going international, we would talk you toward EB double wall.

Do I need tape with a mailer box?
No, the tuck front hold it closed. Most brand still add a branded sticker seal, more for looks and tamper evidence than for holding it shut.

Can you print the inside of the box?
Yes and it is the thing we recommend most. Interior print cost less than people expect and it is what get shared on social.

Will kraft mailer packaging take full color print?
It take print, but the brown ground shift your color. Anything light or bright will look muted. For accurate color go white top or bleached white.

How do I stop my product moving in transit?
Right size first, then insert if needed. A die cut paperboard cradle work for most product and keep the whole thing recyclable.

Whats the difference between a mailer box and a shipping box?
A mailer box is one piece, no tape, printed, made to be seen by customer. A regular shipping box is two piece or RSC, taped, plain, made to be thrown away.

Can we add a tear strip?
We can. It adds a small cost but it make opening much easier and it look considered.