Corrugated Mailer Boxes
Corrugated mailer boxes — a fluted wave glued between two liners, which is where all the crush resistance comes from. The flute size you choose decides both protection and price.
- E-flute 1.5 mm for retail-facing mailers, B-flute 3 mm for heavier goods
- Double wall available for fragile or high-value contents
- Flute direction resolved in the dieline, not left to chance
- Kraft or white-top liner, full-colour print inside and out
- From 50 units, specified to your product weight
- 4–6 working daysClock starts at proof approval
- Artwork checked firstBleed, folds and colour build
- Nothing prints unapprovedYou sign the proof first
- Curbside recyclableUnless you choose a laminate
Get a quote for
corrugated mailer boxes.
Send the dimensions of the product rather than a box you already use — we add the clearance ourselves. Itemised pricing comes back the same working day.
- Priced at several quantities, so you can see where the curve flattens
- Print-ready dieline and a 3D render, at no charge
- We flag it if a smaller dimension would cost you less
| Box style | Self-locking mailer box (Roll End Tuck Front — RETF) |
|---|---|
| Material options | Kraft corrugated, white corrugated, E-flute, B-flute, rigid stock (premium) |
| Flute types | E-flute (1.5mm), B-flute (3mm), custom flute on request |
| Stock thickness | 16pt – 28pt (depending on material selection) |
| Printing options | Offset printing, digital printing, flexographic printing |
| Color options | CMYK (4-color process), Pantone (PMS), inside & outside printing available |
| Finishing options | Matte lamination, gloss lamination, soft-touch lamination, AQ coating |
| Add-ons | Spot UV, foil stamping (gold/silver), embossing, debossing, custom inserts |
| Sizes | Custom sizes available (length × width × depth) |
| Minimum order qty | Low MOQ available — start at 50 units |
| Turnaround time | 4–6 business days (rush available) |
| Shipping | Flat-packed, free shipping available across the USA |
| Eco-friendly | Recyclable & biodegradable options available |
Corrugated mailer boxes — a fluted wave glued between two liners, which is where all the crush resistance comes from. The flute size you choose decides both protection and price.
- E-flute 1.5 mm for retail-facing mailers, B-flute 3 mm for heavier goods
- Double wall available for fragile or high-value contents
- Flute direction resolved in the dieline, not left to chance
- Kraft or white-top liner, full-colour print inside and out
- From 50 units, specified to your product weight
Corrugated board is a sandwich: a wavy fluted layer glued between two flat liners. The wave is the whole point. It resists crushing the way an arch resists load — by turning pressure into tension along a curve — which is how a few millimetres of paper survives a journey that would flatten a solid sheet of the same weight.
Flutes, and why the letter matters
The wave comes in sizes, and the letter tells you which. This is the single most useful thing to understand when specifying a box, because it decides both protection and price.
- E-flute, about 1.5 mm — fine and dense. Thin enough to fold crisply and print cleanly, which is why it is the default for retail-facing mailers.
- B-flute, about 3 mm — noticeably tougher, slightly coarser surface. The step up when contents are heavier or the journey is longer.
- C-flute, about 4 mm — outer cases and shipping cartons, rarely a branded mailer.
- BE double wall, about 4.5 mm — two flutes bonded together for genuinely fragile or heavy goods.
Choosing without over-specifying
Over-specification is the commonest way to overpay for packaging. Heavier board costs more per unit, adds dimensional weight to every shipment, and takes more warehouse space flat-packed. For most direct-to-consumer products under about two kilos, E-flute is the correct answer and anything heavier is money spent on protection the product does not need.
The honest test is what happens on a drop. If your product would survive a metre onto a hard floor inside an E-flute box, you do not need B-flute. If it would not, no amount of void fill compensates for the wrong board.
Grain direction and why boxes fail
Flutes run in one direction, and the board is far stronger across them than along them. A box cut with the flutes running the wrong way for its proportions will bow in the middle and lose its stacking strength. Getting this right is part of the dieline work rather than something you specify — but it is why a professionally engineered box outperforms a generic one of the same grade.
Frequently asked questions
Is corrugated recyclable?
Yes, and it is one of the most recovered materials in the waste stream. Plastic lamination compromises that; a water-based varnish does not.
Can corrugated take full-colour printing?
E-flute takes it very well. Coarser flutes can show a faint washboard texture through heavy ink coverage, which is worth knowing before committing a photographic design to B-flute.
What thickness do I need?
Tell us the product weight and how fragile it is and we will specify it. We would rather talk you down a grade than sell you board you do not need.
Get it specified properly
Send the product dimensions and weight. You get a dieline with the flute direction already resolved, a 3D mockup, and itemised pricing across quantity tiers.
How we build corrugated mailer boxes.
Measured from the product
We size the box around what goes inside and add the clearance it needs. That removes void fill you would otherwise buy and dimensional weight you would otherwise pay on every order.
Colour that behaves
Process CMYK or a Pantone spot match, outside and in. We tell you how a colour will sit on kraft before the run, not after it.
Board matched to the load
E-flute, B-flute or double wall depending on weight and fragility. We will talk you down a grade as readily as up one.
Assembles in one motion
One-piece construction with a front-tab lock. No tape, no gun, and seconds rather than minutes at the packing bench.
Recyclable as standard
Kraft and corrugated go in the curbside bin with water- and soy-based inks. Plastic lamination changes that, and we say so when you ask for it.
Fifty is a real run
Enough to prove a design before committing to thousands. Pricing steps down at 250, 500 and 1,000 as setup cost spreads.
Customization options
Board, print method and finish are three separate decisions, and each one moves the price. We will tell you which are worth paying for on your product and which are not.
Stock & flute
Printing
Finishes
Add-ons
Brands that ship with this box
What customers tell us
"The print quality is unreal and the fit around our product is perfect. Our unboxing posts doubled."
"Low minimum let us test, and the design team caught issues before print. Reordered at 5,000."
"Boxes arrived early, flat-packed and flawless. Free shipping made the math easy. Highly recommend."
