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new Custom Mailer Box - Package N' Go

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A mailer box is a durable paperboard packaging solution, ideal for storing and shipping items. Its unique design with interlocking flaps ensures easy assembly without tape. The double-sided walls provide extra strength for transportation, making it a reusable choice. Crafted mainly from corrugated cardboard, it’s designed to protect contents from external impacts during transit.
-Easy Assembly
-Enhanced Customer Experience
-Customization and Branding

What Mailer Boxes Are

General Applications For Custom Mailer Boxes

Mailer boxes find versatile applications across various industries, making them an ideal choice for a range of products.







The Wire


Fabrics And Yarns


Books And Other Prints


Phone Cases







Hot Selling Types of Custom Mailer Boxes


Tab Lock Roll End

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Insurance Tab Mailer Box

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Roll End 3 Flaps Tuck

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Windowed Mailer Box

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Roll End Tuck Top

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Handled Mailer Box

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Roll End Tuck Front

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Custom-Shaped Mailer Box

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Common Sizes of Mailer Boxes

Small Size (inches)
6 x 4 x 2
6 x 4 x 2
6 x 4 x 2
3 x 3 x 1
8 x 6 x 2
6 x 4 x 2
Medium Size (inches)
8 x 6 x 3
8 x 6 x 4
8 x 6 x 4
4 x 4 x 2
12 x 10 x 3
10 x 6 x 3
Large Size (inches)
10 x 8 x 4
10 x 8 x 6
10 x 8 x 6
6 x 6 x 3
16 x 12 x 4
12 x 8 x 4

Eco-Friendliness Of Mailer Boxes

Package N' Go's mailer boxes stand out for their eco-friendliness. They are fully recyclable and biodegradable, made from recycled materials, and feature non-toxic inks and adhesives. Designed for durability and reuse, these boxes represent Package N' Go's commitment to sustainable and responsible packaging solutions.

Customization Of Custom Mailer Boxes

White Kraft
Black Kraft
Natural Brown Kraft
Corrugated Sheet

Sustainable Inserts


Paperboard Inserts


Molded Pulp Inserts


Corrugated Inserts


Blister Inserts


Foam Inserts


Pearl Cotton Inserts


EVA Foam Inserts



Gloss Lamination


Matte Lamination


Soft Touch


Aqueous Coating

Spot UV
Hot Foil Stamping
Cold Foil Stamping

How Mailer Boxes Are Made

Printing: We begin by printing on your chosen cardboard using flexography for kraft and offset for white cardboard. This process includes multiple color calibrations to ensure accuracy and vibrancy. Optional finishes like spot UV, glitter, or foil stamping are added for a sophisticated touch.

Composite (For Corrugated Mailer Boxes): Next, we composite brown or white cardboard with a corrugated sheet using strong adhesive, followed by flattening and a two-day natural drying process. This ensures strong cohesion and prevents deformation.

Die-cutting: Die-cutting shapes the boxes with precision, using a combination of sharp and blunt blades. We conduct thorough inspections and calibrations to avoid excess pressure and waste, ensuring each box is perfectly crafted.
Box Cutting and Making: Finally, boxes are shaped and offcuts removed. This step is crucial for final assembly and quality. We use specialized equipment for precision, offering both two-dimensional and three-dimensional options based on your preference.

What Design File Shoule Be Prepared

File Format: Preferred formats: AI (Adobe Illustrator) or PDF for high-resolution artwork.
Resolution:Minimum of 300 DPI (dots per inch) to ensure sharp and clear prints.
Color Mode:Use CMYK color mode, which is best for four-color process printing. Avoid RGB mode to prevent color printing issues.
Fonts: Convert all text to outlines or include the specific fonts used to avoid font replacement issues.
Graphic Elements:All logos, photos, and icons should be high quality and correctly positioned. Provide necessary links and avoid using copyrighted images without permission.
Bleed Area: Usually an extra 3 to 5 mm around the edges, to ensure no white margins appear after cutting and printing.

The Process Flow & Duration Estimation


Step 1: Free Design (1 day)

Work with our team to develop a bespoke design that resonates with your brand identity and vision.


Step 4: Production (5-15 days)

Our expert team closely monitors production, ensuring your mailer boxes are crafted to the highest standards within the agreed timeframe.


Step 2: Free Sampling (3-5 days)

We provide a physical sample of your custom mailer box, allowing you to evaluate its look, functionality, and overall quality.


Step 5: Quality Inspection (1-2 days)

Each box undergoes a thorough inspection by our quality control team, upholding our commitment to superior quality standards.


Step 3: Payment

Choose your preferred payment option from our range of flexible methods, tailored to suit your financial preferences.


Step 6: Delivery (3-30 days)

Your custom mailer boxes are carefully packed and dispatched to your location, with various shipping options available to meet your specific needs.

How To Choose The Materials Of Custom Mailer Boxes

Selecting the right material for your mailer box is crucial to ensure that your products are adequately protected and your brand values are upheld. Here's a guide on how to make this important decision:

Consider Product Requirements: Start by understanding the nature of the products you intend to ship. Fragile or valuable items may require a sturdier and more protective material, while lightweight or non-fragile products may allow for more flexibility.
Evaluate Durability: Assess the durability of the materials available. Corrugated cardboard is a popular choice due to its strength and cushioning properties. Consider the thickness (measured in ECT or Mullen test ratings) to gauge the material’s ability to withstand handling and shipping.
Eco-Friendly Options: If sustainability is a priority, opt for materials made from recycled content or sustainable sources. Look for certifications like FSC (Forest Stewardship Council) to ensure responsible sourcing.
Printing And Customization: Consider the printing quality and customization options for each material. Some materials may provide better printing results and vibrant colors, which can enhance your brand’s visual appeal.
Budget Constraints: Balance your material choice with your budget. While premium materials may offer superior protection and aesthetics, they can be more expensive. Assess how your choice aligns with your overall packaging budget.

How To Assess Quality Without Professional Machinery

You don't need specialized equipment to gauge the quality of your mailer boxes. Here's how to assess their quality with simple methods:

1. Printing Quality: Inspect the printing quality, if applicable. Crisp and vibrant printing with accurate colors and clear text demonstrates attention to detail.
2. Tactile Assessment: Run your hands over the box’s surface. Quality mailer boxes should feel sturdy and free from flimsiness. Check for any loose or unglued seams, as well as the overall thickness of the material.
3. Fold And Closure Test: Fold the box along its creases and secure it using the intended closure mechanism (e.g., tabs, adhesive). A secure and snug fit indicates good craftsmanship.

How To Store Custom Mailer Boxes

Dry Environment:
Store the boxes in a dry place to prevent moisture from weakening the cardboard. Excess humidity can lead to warping or mold.
Temperature Control:
Keep the boxes in a temperature-controlled environment. Extreme temperatures can cause the material to expand or contract, affecting the box’s integrity.
Avoid Direct Sunlight:
Store the boxes away from direct sunlight as UV rays can fade the print and weaken the box material over time.
Stack Carefully:
If stacking boxes, do it evenly and carefully to avoid crushing. It’s best to not stack too high to prevent the bottom boxes from bearing too much weight.
Flat Storage:
If possible, store the boxes flat rather than assembled. This saves space and prevents the boxes from becoming misshapen.

Factors That Influence Prices Of Custom Mailer Boxes

Box Size: The size of the box is a crucial factor in cost determination. Larger boxes require more materials and time to produce, leading to higher expenses.
Material Quality: The type of material used significantly influences the price. Specialty materials tend to be more expensive than standard options.
Printing And Customization: The complexity of printing and customization can increase costs. Additional features like die-cut windows or inserts add to the complexity and, consequently, the expense.
Quantity: The number of boxes ordered impacts the cost per unit. Bulk orders typically result in lower per-unit costs due to efficiencies in production.
Everything You Need to Know About Gravure Printing

Table of Contents 1. Introduction to the Process Gravure printing is a direct printing method where ink from the recessed cells of the gravure cylinder is transferred directly onto the substrate. In gravure printing, the image areas of the printing plate are below the surface of the plate, with varying depths corresponding to the tonal variations of the image. The non-image areas are raised and on the same plane. During printing, ink fills the recessed cells, excess ink on the surface of the plate is wiped away by a doctor blade, and the plate is then pressed onto the substrate with sufficient pressure to transfer the ink from the cells onto the substrate, completing the printing process. 2. Process Flow The main steps of the gravure printing process include: 2.1 Design and Plate Making Designing and creating the gravure printing plate according to the requirements of the print job. The plate must be precise, with clear details to accurately transfer the image. 2.2 Plate Making Transferring the designed image onto the plate. Common methods include chemical etching, photomechanical processes, and mechanical engraving. The completed plate is inspected and refined to ensure quality and accuracy. 2.3 Printing Preparation This includes adjusting the plate, setting up the printing press, mixing inks, and selecting the printing substrate, ensuring the smooth operation of the press. 2.4 Printing Placing the prepared plate on the printing press,…

Detailed Explanation of Embossing and Debossing Techniques

Table of Contents 1. Introduction to the Technique Embossing and debossing, also known as relief printing or raised printing, are post-press techniques that create a three-dimensional effect on paper or other substrates. By using pre-made embossing dies and applying pressure, the surface of the substrate is shaped into raised or recessed designs or text. This technique highlights specific areas of a printed piece, making them more prominent and visually appealing. 2. Principle of the Technique Plate Making: First, create the embossing (raised) and debossing (recessed) dies based on the design. This is usually done through engraving, which can involve woodcuts, copper engravings, or steel engravings. The engraving process distinguishes the primary from the secondary layers in the design, using depth to emphasize the main elements and adding details for secondary elements. Embossing and Debossing Process: During printing, place the substrate between the embossing and debossing dies and apply significant pressure. Under pressure, the substrate undergoes plastic deformation, creating raised or recessed designs and text. This process does not use ink but relies on the pressure from the printing machine. Visual Effects: Embossing and debossing techniques create noticeable relief effects, enhancing the three-dimensional feel and artistic appeal of the printed piece. The tactile differences provided by the raised or recessed designs add richness to the visual experience. Additionally, these techniques can produce various shapes and patterns, capturing…

Die-Cutting Process for Paper Products

Table of Contents 1. Process Overview The die-cutting process is a critical technique in paper product processing. It utilizes molds to cut paper, cardboard, and other materials into specific shapes and sizes. Currently, the main die-cutting processes are flat-bed, rotary, and cylindrical die-cutting. Among these, flat-bed and cylindrical die-cutting are the most common. 1.1 Flat-Bed Die-Cutting Flat-bed die-cutting can be divided into vertical semi-automatic die-cutting machines and horizontal automatic die-cutting machines. Vertical Semi-Automatic Die-Cutting Machine: Known for its simple structure, easy maintenance, and ease of operation, this machine is widely used in smaller production facilities. However, it has high labor intensity and low production efficiency, typically operating at 20-30 cycles per minute, making it suitable for small batch production. Horizontal Automatic Die-Cutting Machine: This machine is safe and reliable with a high degree of automation and production efficiency. Due to its small platen stroke, manual loading and unloading of cardboard is challenging, so it usually includes an automatic feeding system. The overall structure is similar to a sheet-fed offset press, consisting of an automatic paper feeding system, die-cutting section, paper output section, and electrical control and mechanical transmission components, sometimes equipped with an automatic waste removal system. It is well-suited for micro-corrugated cartons and paper box forming. 1.2 Rotary Die-Cutting Rotary die-cutting replaces the platen with a cylindrical pressure roller, with the cutting die positioned below the roller.…

Detailed Explanation of the Lamination Process

Table of Contents Introduction to the Process   Principle   Lamination is a surface finishing process in printing, also known as post-press coating, post-press lamination, or post-press film application. It involves covering the surface of printed products with a transparent plastic film (primarily BOPP and PET materials) of 0.012 to 0.020 mm thickness using a laminating machine, forming a paper-plastic composite product through adhesion.   Advantages Enhanced Durability: Lamination enhances the durability of packaging by adding a protective film to paper boxes and gift boxes, effectively preventing scratches, stains, and other damage. This extends the packaging's lifespan and ensures products remain undamaged during transport and storage.   Improved Visual Appeal: Lamination can significantly enhance the visual appeal of packaging. By choosing transparent or colored laminating materials, the packaging can appear more vibrant and attractive, capturing consumer attention and increasing product appeal.   Additional Design Space: Lamination offers extra design possibilities. Using materials with special effects or textures, such as matte or glossy finishes, can add unique and sophisticated elements to the packaging, enhancing the product's perceived quality and value.   Working Methods and Process   The lamination process can be divided into wet lamination and pre-coating lamination based on the materials and equipment used. Wet lamination involves using a freshly applied adhesive, which can be solvent-based or emulsion-based. Pre-coating lamination…

Everything You Need to Know About Biodegradable Poly Mailers

Table of Contents Chapter 1: Understanding biodegradable poly mailers   1.1 What is a biodegradable poly mailer?   A biodegradable poly mailer is an eco-friendly packaging option made from biodegradable materials. It can decompose over time through various techniques like photodegradation, oxidation, and biological degradation, thereby avoiding environmental pollution. These mailers have good transparency, heat resistance, high tensile strength, impact resistance, rigidity, and toughness, with low heat shrinkage rates.   1.2 What are biodegradable poly mailers made of?   The main raw materials for biodegradable poly mailers include natural high molecular weight materials and biodegradable polymers. Specifically, there are several types:   Starch-based plastics: These are made by blending starch and plastics through a specific process. The primary materials are starch and polyethylene, along with certain degradation agents and plasticizers.     Polylactic acid (PLA): This is a biodegradable polyester plastic made from lactic acid through polymerization.   Cellulose: Another natural high molecular weight material, cellulose can also be used to make biodegradable plastic mailers.     Aliphatic polyesters, polylactic acid, polyvinyl alcohol: These are produced from microbial fermentation or synthetic biodegradable polymers.   PBS (polybutylene succinate): This material can be produced using petrochemical raw materials or through fermentation of renewable crops like starch, cellulose, glucose, etc.     These raw materials are extracted from natural plant fibers or biomass…

The Ultimate Guide to Shipping Box

Table of Contents Chapter 1: Understanding shipping boxes   1.1 What is a shipping box?   The shipping box has a straightforward design, formed by folding and creasing a single piece of cardboard. It includes four three-dimensional panels: two long side panels and two short side panels, which can be folded and secured with adhesive tape or other methods. Usually, it also features a lid and a bottom that match its dimensions, enabling complete closure. Shipping boxes are used for packaging and transporting various products, known for their convenience, cost-effectiveness, and efficiency, making them widely used in the logistics industry.   1.2 What are the materials of shipping boxes?   1.2.1 Corrugated cardboard   Corrugated cardboard is one of the primary materials used in making paper boxes. It consists of one or two layers of corrugated cardboard and two or three layers of flat paper. There are various types of corrugated cardboard, classified based on the flute type as A, B, C, E, N, F, and N.     We can refer to the grammage of corrugated cardboard in this form:     1.2.2 Boxboard paper   Boxboard paper is the surface layer paperboard used in corrugated cardboard boxes, requiring high strength and good toughness, made from sulphate pulp. Depending on the quality and usage requirements of the boxes, boxboard…

Everything You Need to Know About Glassine Bags

Table of Contents Chapter 1: Understanding glassine bags   1.1 What is a glassine bag?   Glassine bags are made from glassine paper. Glassine paper is a high-quality specialty paper material known for its dense and uniform texture, high internal strength, good translucency, and other characteristics. It also has functions such as high temperature resistance, moisture resistance, and oil resistance, making it widely used in packaging for industries such as food, clothing, electronics, home decor, and gifts.   1.2 What are the materials of glassine bags?   The raw materials used in manufacturing glassine bags consist mainly of the following components:       Furthermore, the coating materials for glassine paper include:     1.3 What are the uses of glassine bags?   Glassine bags are a versatile packaging solution widely used across various industries and product types. Here are some specific use cases:   Clothing packaging:   Glassine paper packaging bags are particularly suitable for clothing packaging due to their high temperature resistance, moisture resistance, and oil resistance. They can effectively protect clothing from environmental factors.   Environmental packaging:   As a material for eco-friendly, renewable, and plastic-free paper bags, glassine paper bags help reduce plastic pollution and serve as an "environmentally friendly attire" for numerous products.   1.4 Common sizes       1.5 What are the benefits…

Everything You Need to Know About Zip Lock Bags

Table of Contents Chapter 1: Understanding zip lock bags   1.1 What is a zip lock bag?   A zip lock bag is a type of plastic packaging widely used for clothing, shoes, bags, food, cosmetics, medicines, and other products. Its main feature is the zip-lock closure design, which is convenient, quick, and provides good transparency. It can offer a beautiful, clean, and hygienic protection for the goods.   1.2  What are the materials of zip lock bags?   1.2.1 Polyethylene (PE)   PE is a type of plastic material with excellent properties, suitable for making high-pressure plastic bags, tote bags, and more.   Features: PE is soft, non-toxic, easy to dye, impact-resistant (-40°C to 90°C), resistant to moisture, and has good chemical resistance.   The molecular weight of polyethylene depends on its type, with common types including Low-Density Polyethylene (LDPE) and High-Density Polyethylene (HDPE). LDPE typically has a molecular weight between 1000 and 3000, offering good impact resistance and heat resistance, often used in making plastic bags. HDPE typically has a molecular weight between 3000 and 9000, providing good impact resistance, corrosion resistance, and heat resistance.   1.2.2 Polypropylene (PP)   Polypropylene (PP) is a versatile plastic material widely used for manufacturing high-transparency plastic films, self-sealing bags, flat bags, and vacuum-formed boxes. It offers several advantages, including easy colorability,…

Everything You Need to Know About Honeycomb Paper Bags

Table of Contents Chapter 1: Understanding honeycomb paper bags   1.1 What is a honeycomb paper bag?   A honeycomb paper bag is made by bonding three layers: kraft paper, honeycomb paper, and kraft paper again, with honeycomb paper as the primary material. With the growing environmental consciousness, honeycomb paper bags are emerging as a new star in the express delivery and logistics industry, gradually replacing many plastic products due to their eco-friendly and biodegradable nature. These bags feature a hexagonal cell structure similar to a honeycomb, providing lightweight, durable, and eco-friendly packaging solutions for industries such as shipping, logistics, and e-commerce.   1.2 What are the materials of honeycomb paper bags?   1.2.1 Honeycomb paper     Honeycomb paper, also known as honeycomb packaging paper or honeycomb kraft paper, is a type of cushioning protective material made by die-cutting kraft paper into a mesh-like structure that can be expanded into a honeycomb pattern. It is used as an eco-friendly alternative to plastic-based materials like bubble wrap or foam in protective packaging, suitable for shipping, cross-border e-commerce, courier transport, and product packaging, providing strong protection for goods. The paper is initially flat after die-cutting from kraft paper but expands into a honeycomb pattern when used or made into bags.   Honeycomb paper must be made from the long fibers of…

The Ultimate Guide to Rigid Box

Table of Contents Chapter 1: Understanding rigid boxes 1.1 What is a rigid box? A rigid box is a type of high-end packaging known for its exquisite appearance, refined craftsmanship, and intricate structure. It is named for the multiple pasting processes involved in its production. Essentially, pasting involves adhering the box's surface paper to an industrial board. Rigid boxes are renowned for their robust and durable construction, maintaining their shape and integrity even under pressure. They find wide application across various industries, including luxury goods, cosmetics, electronics, jewelry, and gift packaging. These boxes are favored for their ability to convey quality and elegance, making them an ideal choice for high-end products. 1.2 What are the materials of rigid boxes? 1.2.1 Gray board paper Gray board paper, also known as greyboard, is a type of paperboard made from recycled waste paper and is considered an environmentally friendly packaging material. It comes in three main types: single gray, double gray, and full gray. Single gray board has one side that is gray; full gray board is uniformly gray on both sides, including the core; double gray board has gray on both sides, with a yellowish core visible from the cut edge. While double gray and full gray may look similar externally, full gray board tends to have better rigidity. Double gray board is more cost-effective, hence its widespread…

The Basic Knowledge About Mailer Boxes

On our blog, we consistently provide detailed and insightful articles covering numerous facets of custom shipping boxes. Our goal is to furnish you with essential information, enabling you to make informed choices.

What People Say About Our Shipping Boxes

“Just received my order of custom mailer boxes, and I’m beyond impressed! The quality is top-notch, and they perfectly match my brand’s aesthetic. Fantastic job!”
“These custom mailer boxes have really taken my business’s packaging to the next level. Love the durability and how my logo pops on these boxes. Great investment!”
“I was a bit hesitant about ordering custom boxes online, but I’m so glad I did. The customer service was helpful, and the end product is exactly what I envisioned. Highly recommend!”
“I’m amazed at the affordability of these custom mailer boxes! High quality at such a reasonable price is hard to find.”
“These mailer boxes have elevated my brand’s unboxing experience. The attention to detail in the printing and construction is remarkable. Plus, eco-friendly options! Definitely ordering again.”

The Common Pitfalls When Purchasing

Inaccurate Sizing: Ordering boxes that are too small or too large for your products can lead to increased costs or damaged goods.

How to Avoid It: Carefully measure your products and consider any extra space needed for padding or protection before placing your order.

Compromising On Material Quality: Opting for cheaper, lower-quality materials can negatively impact the durability and presentation of your boxes.

How to Avoid It: Ensure you understand the material options and choose one that offers the best balance of quality and cost.

Overlooking Print And Design Quality: Poor print and design quality can diminish your brand's image.

How to Avoid It: Request samples to check the print quality and work closely with the design team to ensure your branding is accurately and attractively represented.

Ignoring Environmental Impact: Neglecting the sustainability aspect of packaging can harm your brand's reputation.

How to Avoid It: Choose eco-friendly materials and practices to show your commitment to the environment.

Underestimating Lead Times: Not accounting for production and shipping times can lead to delays.

How to Avoid It: Always confirm the lead time and factor in extra time for any potential delays to ensure you receive your boxes when you need them.

Not Considering Customization Limitations: Not all designs or customizations may be feasible or cost-effective.

How to Avoid It: Discuss your design ideas with the supplier to understand what is possible within your budget.

A Brief Self-Nomination, Why Choose Package N’ Go?

Package N’ Go, an American company with a robust global footprint, stands out in the packaging industry with over twenty years of excellence. Our innovative supply chain operations, anchored in China, have propelled us to the forefront as an industry leader. Our dedication to delivering customized packaging solutions forms the cornerstone of our success.
Our Competitive Edges Include:
Direct Factory Access
Personalized Service
Minimal MOQ
Cost-Effective Solutions
Rapid Processing
Universal Quality Standards
Round-the-Clock Support
Varied Shipping Options
Flexible Payment Options

What After Sales Service Do We Provide?

01 /

Swift Order Management: At the heart of our service is a commitment to quick and efficient order processing, ensuring that your deadlines are met with ease and reliability.

02 /

Uncompromised Quality Commitment: Our dedication to quality in our custom mailer boxes is unwavering. Should any concerns arise, our devoted quality assurance team is on hand to swiftly address and rectify them, guaranteeing the excellence of our products.

03 /

Hassle-Free Return Policy: Your satisfaction is paramount. In the unlikely event of dissatisfaction with your order, we offer an easy and customer-friendly returns and refunds policy, ensuring a smooth and satisfactory resolution.

04 /

Real-Time Order Monitoring: With our service, you’ll receive continuous updates and real-time tracking of your order. This transparency allows you to stay well-informed about every stage of your custom mailer boxes’ production and delivery journey.

The FAQs About Custom Mailer Boxes

Our mailer boxes can be customized with tamper-evident features like security seals or tear strips to provide added protection and indicate if the box has been opened during transit.
The weight-bearing capacity of mailer boxes varies depending on their dimensions, materials, and structural design. Selecting the appropriate mailer box size and weight capacity for your specific product is crucial to ensure secure and safe shipping.
Certainly, mailer boxes are an excellent option for shipping delicate items. We offer customization options such as added padding or dividers to safeguard your items during transit.
Mailer boxes are designed for easy assembly and typically require no tape or adhesive. They often feature tabs, locks, or self-sealing mechanisms for quick and straightforward setup.
Yes, mailer boxes can be used for international shipping. However, it’s crucial to ensure they meet the packaging and weight requirements of your chosen shipping carrier.

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