Custom Mailer Boxes: Everything You Need to Know

Custom mailer boxes have become the gold standard for e-commerce packaging. They combine protection, branding, and unboxing experience into one efficient package. Whether you're shipping skincare, apparel, accessories, or subscription products, this comprehensive guide covers everything you need to know about mailer boxes.

What Are Custom Mailer Boxes?

Mailer boxes are self-locking, corrugated boxes designed specifically for shipping products directly to customers. Unlike standard shipping boxes, they're meant to be seen—serving as both protection AND presentation.

Key Features of Mailer Boxes:

• Self-locking design: No tape needed for assembly
• Tuck-top closure: Easy open, professional look
• Corrugated construction: E-flute or B-flute for protection
• Fully customizable: Inside and outside printing available
• Flat-pack shipping: Efficient storage before use

Types of Mailer Boxes

1. Standard Tuck-Top Mailers

The most popular choice for e-commerce. Features a tuck-in flap closure.

Best for: Apparel, accessories, general merchandise

Price range: $0.45-$1.50/unit

2. Roll-End Tuck-Top (RETT)

Premium option with full flaps on both ends for enhanced protection and presentation.

Best for: Fragile items, luxury products

Price range: $0.60-$2.00/unit

3. Tab-Lock Mailers

Features interlocking tabs for secure closure without adhesive.

Best for: Subscription boxes, easy-return products

Price range: $0.50-$1.75/unit

4. Literature Mailers

Slim profile designed for flat items like books, prints, or documents.

Best for: Books, prints, flat products

Price range: $0.35-$1.00/unit

Choosing the Right Size

Proper sizing is crucial for both cost efficiency and customer experience.

Standard Mailer Box Sizes

How to Determine Your Ideal Size

1. 1Measure your product at its largest dimensions
2. 2Add 0.5-1" on each side for cushioning
3. 3Consider inserts: Will you use tissue paper, foam, or cards?
4. 4Plan for variants: Choose a size that works for your product range

Pro Tip: A slightly larger box filled beautifully looks better than a tight-fitting box that's difficult to unpack.

Material Options

Corrugated Grades

• E-Flute (1.5mm): Standard choice, excellent print quality
• B-Flute (3mm): Extra protection for heavier items
• F-Flute (0.8mm): Ultra-thin, premium print surface

Paper Types

• Kraft (Brown): Natural, eco-friendly, cost-effective
• White Coated: Bright colors, premium appearance
• Black: Luxury look, dramatic unboxing

Sustainability Options

• FSC Certified: Responsibly sourced paper
• Recycled Content: 30-100% post-consumer materials
• Soy-Based Inks: Eco-friendly printing
• Plastic-Free: No laminations or coatings

Design Best Practices

Outside Design

1. 1Logo Placement: Center-top for immediate brand recognition
2. 2Color Psychology: Use colors that reflect your brand personality
3. 3White Space: Don't overcrowd—let your design breathe
4. 4Contact Info: Include website and social handles

Inside Design

The inside is where the magic happens. Options include:

• Full interior print: Complete coverage for luxury feel
• Thank you message: Personal touch customers remember
• Instructions: Unboxing guide, product care tips
• Social media callout: Encourage sharing with hashtags

Design Elements That Boost Sharing

Instagram-worthy packaging drives free marketing:

1. 1Surprise pop of color inside
2. 2Clever copy that makes customers smile
3. 3Photography-friendly patterns
4. 4Branded tissue paper pairing suggestion

Printing Options Explained

Digital Printing

• Best for: 100-1,000 units
• Benefits: No setup fees, full-color standard
• Limitation: Slightly higher per-unit cost at scale

Offset Printing

• Best for: 1,000+ units
• Benefits: Lower cost at volume, Pantone matching
• Limitation: Setup fees, color minimums

Finishing Options

Cost Breakdown for Mailer Boxes

Factors Affecting Price

1. 1Size: Larger = more expensive
2. 2Quantity: Higher volume = lower unit cost
3. 3Print coverage: More ink = higher cost
4. 4Finishing: Premium finishes add cost
5. 5Material grade: Thicker = more expensive

Sample Pricing (250 quantity)

Assembly and Usage Tips

Efficient Assembly

1. 1Pre-fold boxes during slow periods
2. 2Create an assembly station with all supplies ready
3. 3Train staff on proper technique to avoid damage
4. 4Store flat until needed to save space

Packing Best Practices

1. 1Tissue paper first: Creates anticipation
2. 2Product centered: Focus attention
3. 3Include extras: Cards, samples, notes
4. 4Secure without tape: Use crinkle paper or tissue

Common Mistakes to Avoid

1. Wrong Size Selection

• Too small: Difficult packing, damaged products
• Too large: Wasted materials, shifting contents

2. Ignoring the Inside

The interior is your secret weapon. Don't leave it blank!

3. Skipping Samples

Always get physical samples before ordering. Colors look different on screen.

4. Over-Designing

Clean, simple designs often outperform busy, cluttered ones.

5. Forgetting Functionality

Beautiful packaging means nothing if it's hard to open or damages products.

Mailer Boxes vs. Shipping Boxes

Verdict: Use mailer boxes for direct-to-consumer. Use shipping boxes when packed inside another box or for B2B shipments.

Getting Started with Custom Mailers

Ready to create your custom mailer boxes? Here's your action plan:

1. 1Define your needs: Size, quantity, budget
2. 2Gather inspiration: Save designs you love
3. 3Request samples: Feel different materials and finishes
4. 4Work with designers: Bring your vision to life
5. 5Start small: Order 100-250 to test before scaling

At Brisk Packaging, we make the process simple:

• Free design assistance
• Free 3D mockups before production
• 100-unit minimum orders
• 7-10 day turnaround
• Free shipping

Your packaging is your first physical brand touchpoint. Make it count.