| Box Style | As Mention Above |
|---|---|
| Dimension (L + W + H) | All Custom Sizes & Shapes |
| Minimum Run ( For Boxes and Mylar Bags) | 100 Boxes - 1000 Mylar Bags ( 500 each design) |
| Paper Stock | 10pt to 28pt (60lb to 400lb) Eco-Friendly Kraft, E-flute Corrugated, Bux Board, Cardstock |
| Printing | No Printing, CMYK, CMYK + 1 PMS color, CMYK + 2 PMS colors |
| Finishing | Gloss Lamination, Matte Lamination, Gloss AQ, Gloss UV, Matte UV, Spot UV, Embossing, Foiling |
| Included Options | Die Cutting, Gluing, Scored,Perforation |
| Additional Options | Eco-Friendly, Recycled Boxes, Biodegradable |
| Proof | Flat View, 3D Mock-up, Physical Sampling (On request) |
| Turnaround | 7 - 8 Business Days |
| Shipping | FLAT Position |
What Is a Corrugated Mailer Box?
A corrugated mailer box is a die-cut box that ships flat and locks shut without tape.
The side walls roll up from the base, giving you double-thickness walls at the edges. The lid tucks into a front slot and holds itself closed. This construction is called a roll-end tuck top, or RETT, and it is the most common mailer box design.
Three things make it the standard for online retail:
- Double-wall strength at the edges without paying for double-wall board
- A lid that opens like a book, so the arrival feels deliberate
- Flat storage, so you are not paying for warehouse air
Most custom mailer boxes are built on E-flute, a fine, dense corrugation about 1 to 1.5 mm thick. It prints cleanly and stores about twice as many boxes per pallet as B-flute. Choose a B-flute instead when your contents are heavy or fragile.
Why Tape-Free Mailer Boxes Save Labour
Assembly time is the cost most brands never measure.
A mailer box folds together in seconds. No tape, no tape gun, no consumable to reorder. A standard shipping carton needs taping on the top and bottom on every order.
Per order, the difference is small. across a few hundred orders a week, it becomes real labour.
Two things affect this more than people expect:
Scoring quality. A properly scored box folds cleanly and locks first time. A poorly scored one fights your packer on every unit.
Right-sizing. A box that fits your product needs little or no void fill. That removes the filler cost and the seconds spent stuffing it.
If you ship several product sizes, three well-chosen mailer box sizes usually beat one compromise size.
How Mailer Box Size Drives Your Shipping Cost
This is where the real money sits, and almost no mailer box page covers it.
Couriers do not just charge by weight. They charge on whichever is higher: your actual weight, or your dimensional weight, a figure calculated from the box's volume.
The formula is length × width × height, divided by a divisor your carrier sets. Common divisors are 139 for imperial and 5000 for metric. They vary by carrier, service and contract, so check your own agreement.
Here is what it means in practice.
Most eCommerce parcels are light products in a box. Dimensional weight wins, which means you are paying freight on the empty space inside your mailer boxes on every shipment you send.
A box 2 cm smaller in each dimension can drop below a rate threshold. Across a hundred orders a week, that saving dwarfs anything you gained by choosing cheaper board.
This is why custom mailer boxes often beat a stock size that nearly fits. The stock box is cheaper per unit. It is more expensive per delivered order.
Send us your product dimensions and your carrier's divisor. We will build the box around your product, not around a size chart.
Choosing the Right Flute for Your Mailer Boxes
Damage is the most expensive outcome in the chain. You lose the product, the replacement shipment, and often the customer.
Mailer construction already helps those rolled side walls double the board at the edges, and edges are where crush damage starts.
Three variables decide the rest:
Flute and wall. E-flute single-wall handles most consumer goods. Move to the B-flute for heavier items. Only go double-wall when weight or fragility truly demands it over-specifying adds material cost and freight weight to every order you ever ship.
Fit. A product that slides around takes the same impact repeatedly. A snug fit prevents more damage than a heavier board does.
Inserts. Corrugated inserts and dividers hold products still and keep multiple items apart. For glass, ceramics and multi-piece sets, they are essential.
If you are seeing transit damage, look at fit before board weight. Fit is usually the cheaper fix.
Printed Mailer Boxes, Inside and Out
Every competitor writes about this stage. Here is the short version, plus what they leave out.
The mailer opens like a book. One clean reveal, no knife, no scramble.
Print the inside. This is the most underused surface in packaging. The inside of the lid is what your customer looks directly at, for several seconds, with the product still in place. A message or pattern there works harder than anything on the exterior, which someone glanced at while carrying it up a path.
The part nobody mentions: heavily printed mailer boxes advertise value to the courier network as well as to your customer. Some high-value brands deliberately keep the outside plain and put the entire design inside. Decide which risk matters more for your category.
Print methods for custom mailer boxes:
- Digital no plate cost, best for short runs and variable designs
- Economical at volume, strong on solid colours, logos and type
- Litho lamination full photographic quality where the artwork demands it
Fine flutes print well. Coarse flutes show faint ribbing called washboarding. That is one more reason the E-flute is the mailer box standard.
Return-Ready Mailer Boxes
Returns cost money. The right mailer box reduces that cost.
A double adhesive strip lets your customer reseal the same box and send it back. You do not supply return packaging, and the item is likelier to arrive back in sellable condition.
A tear strip opens the box cleanly without a knife, protecting both the product and the box.
Worth it for apparel, footwear and anything with a real return rate. Skip it if returns are rare in your category.
Are Corrugated Mailer Boxes Recyclable?
Yes, corrugated is among the most successfully recovered packaging materials in Canada. Collection streams are well established, and kraft fibres survive several recycling cycles.
A plain or flexo-printed mailer box with water-based ink goes straight into the paper stream. Nothing to separate.
What breaks that: plastic film lamination, heavy wax coatings, and plastic tape or labels left on the box.
If recyclability is part of your brand promise, choose aqueous coating over film and paper-based tape over plastic.
The biggest environmental lever is also the one that cuts your freight bill. A right-sized box uses less board, needs less filler and takes less room on the truck. Cost and sustainability point the same direction here.
Custom Mailer Box Sizes: Getting the Numbers Right
Three rules prevent most ordering mistakes.
Dimensions are internal. Length × width × depth, measured inside the box. Board thickness is added on top.
The order is fixed. Length is the longer side of the opening, width the shorter side, and depth from opening to base. Mix them up and you get the right volume in the wrong shape.
Leave clearance. A few millimetres around the product, plus room for tissue or filler. A box built to exact product dimensions will not close comfortably.
Send us dimensions and weight together. Dimensions set the size. Weight sets the board.
Kraft, White and Printed Mailer Boxes
Kraft mailer boxes are the most economical. They hide scuffs and courier marks better than anything else. Ink shifts warm over brown board, so they suit one and two-colour designs rather than exact brand colours.
White mailer boxes use a white-top liner, a bleached printing surface over a kraft base, with a brown interior. This is what most branded white mailers are, and it is the sensible middle choice.
Fully bleached board is white inside and out. It costs more, and it earns that when the interior is central to your presentation.
One caution: white shows every mark that kraft hides. If your boxes ship without an outer carton, plan for it or add a coating.
Who Uses Custom Mailer Boxes
Subscription box brands, where the arrival is the monthly product experience. Apparel and footwear, for shipping and returns. Cosmetics and skincare, for launches and gift sets. Electronics and accessories, with inserts. Coffee, tea and speciality food, for direct sales. Candle brands, with dividers for multi-piece orders. Corporate gifting and onboarding kits.
Need a shipping case rather than a presentation box? Our corrugated packaging page covers RSC and other freight-focused styles.
Why Order Corrugated Mailer Boxes From Us
- Built to your dimensions, not fitted to a stock size that is what makes the freight savings possible
- 50-unit minimum, so a launch run or a size test is affordable
- Die cutting, plates, scoring and dielines included a custom size that costs no more to tool than a standard one
- Free design support, including structural dielines and print-ready artwork
- Free digital proof and 3D mockup on every order, with physical samples on request
- 8 to 12 business days from proof approval, or 4 to 6 with rush
- Free shipping across Canada, delivered flat
Get a Custom Mailer Box Quote
Send us your product dimensions and weight, roughly how many units you need, and whether you want interior printing, a tear strip or a return strip.
We will size your corrugated mailer boxes to cut dimensional weight, recommend the flute, quote it, and send a free proof before anything prints.
