Shipping Mailer Box
Shipping mailer boxes specified for what a parcel actually goes through: sorting belts, chutes, stacking under load, and being handled by people who cannot see what is inside.
- Board grade matched to weight and journey length
- E-flute, B-flute or double wall depending on contents
- Square construction that holds up under stacking
- Flat-packed so freight is paid on board, not air
- From 50 units, quoted with delivery included
- 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
shipping mailer box.
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 |
Shipping mailer boxes specified for what a parcel actually goes through: sorting belts, chutes, stacking under load, and being handled by people who cannot see what is inside.
- Board grade matched to weight and journey length
- E-flute, B-flute or double wall depending on contents
- Square construction that holds up under stacking
- Flat-packed so freight is paid on board, not air
- From 50 units, quoted with delivery included
This page is about transit, not branding. A parcel between your unit and a customer’s door is sorted mechanically, dropped onto belts, stacked under other parcels and moved by people with no idea what is inside. Packaging that survives that is specified for it rather than hoped at.
What actually damages parcels
Rarely a single dramatic event. Usually three ordinary ones.
- Corner impact. Parcels land on corners, and a corner concentrates the whole weight into a small area. This is what splits boxes.
- Stacking load. A box near the bottom of a cage carries everything above it for hours. Crush resistance is a board property, and it is the one people under-specify most.
- Internal movement. A product loose inside a box hits the walls repeatedly for the whole journey. Most “damaged in transit” claims are really sizing failures.
Specifying against those three
Corner and crush resistance come from flute grade — that is what you are buying when you step from E-flute to B-flute or double wall. Internal movement is solved by sizing and inserts, not by more board. Our note on choosing the right board sets out where each grade earns its cost.
The honest test: if the product would survive a metre drop inside the box you are considering, the board is right. If it would not, no amount of void fill compensates.
The cost that repeats forever
Carriers bill on whichever is greater, actual weight or volumetric weight. An oversized box therefore costs you on every single shipment, permanently, for space that is doing nothing. Trimming a box that ships hundreds of times a month is one of the few packaging decisions with a measurable payback.
Frequently asked questions
Do I need double wall?
Only for heavy, fragile or high-value goods. On a light product it adds cost and dimensional weight without adding useful protection.
Is corrugated waterproof?
No. Paper absorbs moisture and wet board loses most of its crush resistance. A coating helps briefly; nothing here is built for prolonged wet.
Can you match a size I already use?
Yes, but send the product dimensions too. Existing boxes are often the wrong size and we would rather tell you than copy the mistake.
Quote it against the real journey
Tell us the weight, the fragility and roughly how far it travels, and we will specify board to that rather than to a default.
How we build shipping mailer box.
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."
