Custom Mailer Boxes: Branded Shipping Packaging for E-Commerce

Custom mailer boxes are custom-made boxes made of corrugated cardboard with a flip-top lid for your product, featuring your branding. They are simple to ship, can be put together inside of seconds, and secure orders in transit. 

They are easy to ship, can be assembled within seconds, and secure orders during transit. Select single-wall kraft or white board to use lightweight products and add an insert to the fragile products.

All online orders culminate in one thing: a customer opens a box. When the box is generic, the brand vanishes. When it is printed, made to fit the product, and constructed to withstand a carrier network, the box does marketing, protection, and retention simultaneously. Empress Packaging is a USA-based manufacturer of bespoke mailer boxes, created to be e-commerce brands around the real product, and the volume of orders rather than a volume chart.

What are Custom Mailer Boxes?

A Mailer boxes is a corrugated cardboard box that is intended for shipping a product without an outside carton. It is unfolded, folds up without the aid of tape or glue and folds or snaps its lid shut. Print is attached to the box, which is the shipping container itself.

The most common type is the flip-top mailer, or roll-end tuck-top box. The lid is hinged and fits like a book, but can be secured with a tuck flap. Typically mailers are made of corrugated board, in kraft or white, and the thickness of the fluting (the wavy layer between the layers) will determine amount of cushioning and quality of print.

Why Not Use Custom Mailer Boxes as a Replacement for Standard Shipping Boxes?

The warehouse is constructed with standard shipping boxes. They guard a product between the dock and doorstep and do not do anything to enhance the customer experience. There are three things that printed mailer boxes alter:

• Fit: A box cut to your product eliminates the air that allows things to move around, and it does not incur carrier fees due to air.
• Presentation: Printing transforms the initial physical touchpoint into a branded experience, and this is where unboxing begins.
• Efficiency: Flat-shipped mailers occupy a portion of the warehouse space that pre-assembled boxes would require, and are easy to assemble when packing.

Style

How it close

Best for

Strength level

Typical use

Flip-top mailer (roll-end tuck-top)

Hinged lid with tuck flap

Most e-commerce products

Single-wall standard

Apparel, beauty, accessories

Mailer with tear strip

Lid plus perforated stri

High-return categories

Single-wall standard

Fashion, footwear accessories

Mailer with insert

Lid plus die-cut or paperboard insert

Fragile or multi-item orders

Single-wall with insert

Skincare bottles, candles, electronics accessories

Kraft mailer

Hinged lid, unbleached board

Natural or minimal brands

Single-wall standard

Food gifts, candles, apparel

White printed mailer

Hinged lid, bright print surface

Full-color brand identity

Single-wall standard

Beauty, subscription, DTC brands

Heavy-duty mailer

Reinforced lid, thicker board

Heavier products

Higher wall or flute spec

Home goods, bulk kits

Benefits of Custom Printed Mailer Boxes

• Branding: Cardboard Mailer Boxes present your logo, colors and message on every and each doorstep and each and every unboxing photo, with no additional insert or sticker.
• Protection: The box is the same size as the product, the correct flute, and an insert is used if required, helps to prevent any shifting or crushing, the number one cause of damage claims.
• Right-size Boxes: Will save on void fill material and have the potential to save on dimensional weight charges (which are based on volume as well as weight).
• Materials: Recyclable corrugated, recycled content board, and FSC certified materials are available. The printing that is used is water based, and the box does not contain plastic lamination, simplifying its recycling.
• Customer experience: Easy to open and looks like it`s meant for something, leads to higher perceived value and repeat purchases.

Applications of Custom Mailer Boxes.

Lightweight Flip Top Mailer Packaging are used by apparel and accessories brands, and they can have tear strips to facilitate returns. Bottles and jars are placed in mailers with inserts to keep them in place at beauty and skincare brands. Subscription companies consider the mailer as the whole brand experience, as the box is the first thing that a subscriber views every cycle. Kraft mailers provide a natural appearance at an affordable cost to candle, food gift, and home goods brands. Sellers of electronics accessories combine mailers with paperboard or foam inserts to prevent movement without bulk.

Customization Options

• Material and board: There are kraft, white, and printed corrugated stock. Selection of flute varies with the product: thinner flutes give more printable results, whereas thicker flutes are more cushioning.
• Size: Boxes are cut to the product and typical order combination. It is important to get the size correct prior to production, as an oversized box will waste the material, whereas a tight box can damage the product.
• Printing: Prices go as low as one-color branding on kraft to full-color exterior and interior prints. The cost-effective method of placing a message or pattern on the unboxing is printing it on the inside of the lid.
• Finishes: Finishes can be either matte or gloss, and both finishes influence recyclability, so decisions on finishes are verified against any sustainability claims you are going to make.
• Inserts: Products are held fixed in die-cut corrugated inserts, paperboard dividers, and foam options.
• Closures: Depending on your requirements for returns and wearability, there are standard tuck, tear-strip, and reinforced seam options.

How to Choose the Right Mailer Box?

Start with the product, not the artwork. The board strength is determined by weight and fragility. The volume of orders determines the print technique that is economically viable. And the sales channel will determine the amount of finish to pay an interior print subscription brand will be well-served by a rich interior, whereas a high-volume apparel store might be better served by a single-color brand on kraft. Just in case, request sample proofs of two alternatives prior to a full run.

Frequently Asked Questions

Q: What is a flip-top mailer box?

A: A flip-top mailer is a corrugated box with a hinged top that folds up and folds down. It is the most typical e-commerce style, ships flat, assembles without tape, and is the most popular.

Q: What is the difference between a mailer box and a shipping box?

A: A shipping box is a simple carton constructed to be transported. A mailer box is a package that the customer is meant to see as branded; it has a printed surface and a hinged lid, and it also secures the product during transit.

Q: Are mailer boxes robust enough to be shipped without an outer box?

A: Yes, in the case of matching the weight of the product with the board and flute, and the box is the right size. Fragile or heavy objects might require a more powerful spec or an insert.

Q: What are the minimum quantities of custom mailer boxes?

A: It is based on size, print complexity, and finish and is verified at quoting.

Q: Will I be able to receive a sample prior to a full order?

A: Yes, there is evidence available prior to production runs.

Q: Are mailer boxes eco-friendly?

A: Yes. Most sizes can be made with recyclable kraft, recycled-content board, and FSC-certified stock.

Q: What do I do to select the correct box size?

A: Give the length, width, height, and weight of your product. The product plus the protection it requires are cut around the box, and the size is ensured before production.

Q: Is it possible to print on the inside of the box?

A: Yes. A typical method of adding a message, pattern, or return instructions is by interior printing.

Get Your Free Quote

Free quotes on custom printed boxes at empresspackaging.com, or send us an email query@empresspackaging.com, or call (888) 900-7629.