Mailer boxes

The mailer box is the standard e-commerce format: it folds up by hand, needs no tape and gives a clear unboxing. The details of the structure decide how well it survives transport.

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Corrugated mailer box with the lid open and a printed interior

Structure and assembly

The most common version is a roll-end tuck top, where the sides roll in and the lid locks at the front edge. It assembles in seconds without tools or tape. Double-folded side walls add strength at the corners, which is where damage usually occurs.

Dimensions and contents

Low height for garments and textiles, which lowers volumetric weight.
Slightly taller formats with inserts for hard or fragile products.
Height can often be adjusted without new tooling if length and width stay the same.
Check that the box fits letterbox formats if that is the goal.

Printing inside and out

Flexo printing directly on the corrugated is cost-effective for a logo and simple graphics. Litho lamination, where an offset sheet is laminated to the corrugated, gives photographic quality but costs more. A printed interior in a dark or saturated colour is one of the cheapest ways to lift the unboxing.

Conditions

MOQ around 250-300 units depending on format and print method.
Lead time normally 6-8 weeks after confirmed design.
Flat delivery keeps storage needs small relative to volume.

Detail of the mailer box tuck lock and folded side wings

Material, structure and finish in detail

We review board quality, thickness, fit, print technique and finishing with you and turn it into a specification a supplier can produce against.

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FAQ

Frequently asked questions

Does a mailer box need tape?: No, the lock holds in normal handling. For heavier contents or long transport we recommend an adhesive strip or paper tape.
Which flute should I choose?: E-flute for light products, B-flute as an e-commerce standard, BC-flute for heavier or fragile goods.
Can the mailer box be used for returns?: Yes, if it has two adhesive strips and a tear perforation. That should be decided before tooling is made.
Can the interior be printed in full colour?: Yes. Single colour is cheapest; full colour usually needs litho lamination and higher volumes to be economical.

E-commerce packagingIn e-commerce the packaging carries both the brand and the transport. Dimensions, closure and void fill decide freight cost, damage rates and how the unboxing feels.Read more Return packagingReturn packaging must open without tools and reseal without tape. Two adhesive strips and a well-placed tear perforation are the whole mechanism, but they have to sit correctly.Read more Inserts and void fillDamage happens when the product moves. An insert that holds the product in place is nearly always more effective, and cheaper over time, than adding more void fill.Read more PrintPrint method follows volume and material; finishing follows the impression the packaging should give. The right combination matters more than more colours.Read more

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