Custom Mailer Boxes & Wholesale Packaging
Corrugated mailer boxes, rigid boxes, shippers and custom inserts — all cut to your own dimensions and printed to your brand. Browse the range and request wholesale pricing on any style.
The short version
- Pick the board by weight and fragility, not by price — over-specifying is the commonest way to overpay.
- Unit price drops in steps, so 500 often costs far less per box than 250.
- Every listed size can be made to your own dimensions instead.
- Free dieline, 3D mockup and itemised pricing with every quote.
Which box style do you need?
Most of this catalogue is variations on one structure. A custom mailer box is cut from a single sheet of corrugated board, arrives flat, folds without tape and locks with a front tab. Work from the product outwards — how heavy it is, and how much it would mind being dropped.
| Style | Board | Best for |
|---|---|---|
| Mailer box — E-flute | 1.5 mm | Apparel, accessories, cosmetics, printed matter. Thin, folds crisply, best print surface. |
| Mailer box — B-flute | 3 mm | Heavier or breakable items, or long courier journeys. Noticeably tougher, slightly coarser print. |
| Double-wall shipper | 4.5 mm | Heavy, fragile or high-value goods. Two bonded flutes for serious crush resistance. |
| Rigid box | 16–28 pt | Gift, PR and premium launches. Does not fold flat and costs several times more — worth it when the box is part of what you are selling. |
| Custom insert | Board / foam | Stops movement entirely. Usually cheaper than the volume of loose filler it replaces. |
How wholesale pricing works
Every packaging price is a fixed setup cost plus a per-unit running cost. Setup — cutting the die, making plates, calibrating the press — costs the same whether you order 100 boxes or 10,000. So it is the division by quantity that moves your unit price, not the board.
| Quantity | Setup share of unit price | Typically ordered by |
|---|---|---|
| 50 — our minimum | Highest — setup dominates | Testing a design before committing to it |
| 250 | Noticeably lower | A first real run for a new product |
| 500 | Lower again — the common sweet spot | Where most growing brands land |
| 1,000 | Nearly marginal | Steady monthly shipping volume |
| 2,500+ | Flat — you are paying for board | Established volume; savings now come from materials |
The step from 250 to 500 usually saves more per box than the step from 1,000 to 2,500.
Ordering a size that is not listed
Every product here can be made to your own internal dimensions — the listed sizes are starting points, not a fixed range. Send the length, width and height of the product rather than a box you already use, and we add the clearance and board thickness ourselves.
You get a print-ready dieline, a 3D mockup and itemised pricing back at no charge. If trimming a few millimetres would fit more boxes per sheet and drop your cost, we will tell you before anything is printed.
Any size, made
to order.
Send the product dimensions and a quantity — we engineer the dieline around it and quote wholesale pricing the same working day.