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The Ultimate Guide to Mailer Box - Package N' Go

The Ultimate Guide to Mailer Box

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In the ever-evolving world of commerce, packaging is no longer just a means to an end. It has transformed into a powerful tool that influences customer perceptions, enhances brand identity, and elevates the entire shopping experience. At the heart of this packaging revolution lies the mailer box – a versatile and sturdy solution that has captured the attention of brands across industries.


This guide is your one-stop resource to mastering the art of mailer boxes, and we will embark on a journey into the realm of mailer boxes, exploring their significance, advantages, materials, customization options, and much more.


So, if you’re ready to delve into the world of packaging innovation and discover how mailer boxes can revolutionize your business, let’s begin this enlightening exploration.


What Is a Mailer Box?


A mailer box is a specialized paperboard packaging solution designed for storing and shipping products. Its innovative design features interlocking flaps and wings, allowing for easy assembly and closure without the need for adhesive tape. With its double-sided walls, it offers enhanced durability and resistance during transportation, making it a reusable option.


This versatile and robust packaging solution goes beyond conventional shipping containers. It is carefully crafted to ensure the secure transit of products from sellers to end consumers, offering remarkable protection against potential external impacts that products might face throughout their journey. Typically crafted from corrugated cardboard, this packaging marvel guarantees exceptional safeguarding of items.


Why The Right Mailer Box Is Crucial


Importance of Mailer Box


When customers make a purchase, they aren’t just buying the product itself; they’re investing in the entire experience. From the enticing product images online to the smooth checkout process and order confirmation, right through to receiving the package and unboxing it – every step contributes to the overall experience.


Now, you might be wondering, why choose a mailer box specifically? Well, the answer lies in the advantages of mailer box.



Advantages of Mailer Box


Cost-Effective Shipping


These boxes are superheroes when it comes to shipping! Lightweight yet strong, they keep your shipping costs in check. Plus, their compact design helps save space in storage, making them an economical choice for businesses.


Unforgettable Unboxing Experience


Let’s face it; the moment of unboxing is a big deal! Mailer boxes are masters at making it a memorable experience. Customers can’t wait to tear open the box and be greeted with a beautifully presented package. It’s like unwrapping a gift and leaves them feeling super happy! They might even share their excitement on social media, spreading the love for your brand!


Enhanced Brand Visibility


Mailer boxes offer a unique canvas for showcasing your brand identity. With ample surface area for logos, designs, and promotional messages, they create a powerful branding opportunity. As your packages journey through transit and arrive at their destinations, your brand’s presence is consistently reinforced, increasing brand recognition and recall.


Efficient Storage and Inventory Management


Mailer boxes are designed with efficiency in mind. Their stackable and space-saving nature optimizes storage capacity, allowing businesses to manage inventory seamlessly. With uniform sizes and easy identification, organizing and accessing products become streamlined, contributing to smoother operations.


Convenient Returns and Exchanges


Mailer boxes play a crucial role in the reverse logistics process. Should customers need to return or exchange products, these boxes simplify the procedure. Their easy-to-open design and secure closure make repackaging hassle-free, enhancing the overall customer experience and fostering customer loyalty.


Types Of Mailer Box


Classified By Material


A mailer box exhibits a three-layer composition, encompassing an inner fluted layer embraced by two flat linerboards.

Flat Linerboards


Kraft: Diverse linerboard options are at your disposal for crafting mailer boxes, with prominent selections including kraft, standard white, and premium white.


Derived from 100% recycled materials, kraft linerboard boasts a timeless brown aesthetic. Particularly suited for promoting organic products, it’s an ideal choice. However, it’s worth noting that bright colors printed on kraft may exhibit a more subdued appearance.


Standard White: Often referred to as whitetop, standard white linerboard features a matte finish. It seamlessly complements all color schemes, making it versatile for various designs. Notably, standard white is more adept at accommodating color-intensive images compared to kraft.


Premium White: Recognized as CCNB, premium white linerboard boasts a delicate coating that imparts heightened brightness and glossiness. This variant shines brightest when showcasing vibrant full-color designs. Opt for premium white to ensure the vividness of your diverse and bold color palette stands out impeccably.

Inner Corrugated Sheet


Corrugated boxes offer both single fluted layers and double fluted layers as options. However, for mailer boxes, a single fluted layer is recommended, as excessively thick corrugated sheets can hinder folding and assembly, affecting packaging efficiency. The commonly used corrugated types for mailer boxes include B-flute, C-flute, and E-flute. Opt for the appropriate thickness based on the fragility of your product.


Corrugated boards can be selected for various product packaging and transport needs, and they can also be combined with different flat boards to achieve a multitude of structural designs and appearance effects. The selection of corrugated board type is crucial as it determines the strength, durability, and protective qualities of the packaging.


Classified By Style


Tab Lock Roll End: The Tab Lock Roll End mailer box features a roll end design for secure closure, and it also includes tabs that lock into place, providing additional strength and stability.


Roll End 3 Flaps Tuck: The Roll End 3 Flaps Tuck mailer box has three flaps on the top lid that tuck into the front panel, creating a secure closure.


Roll End Tuck Top: The Roll End Tuck Top mailer box features tuck flaps on the top lid that fold inward and tuck into the front panel, providing a reliable and convenient closure.


Roll End Tuck Front: The Roll End Tuck Front mailer box has tuck flaps on the front panel that fold inward and tuck into the top lid, securing the box for transit. This design is often chosen for products that require a tamper-evident closure.


Materials of Mailer Box


Recyclable Materials


At the forefront of our commitment to environmental responsibility, we proudly offer mailer boxes constructed from 100% recycled corrugated sheets. By utilizing these recyclable materials, we contribute to the reduction of waste and the conservation of valuable resources. This choice not only aligns with sustainable practices but also ensures that our packaging solutions meet the highest standards of eco-friendliness.


Suggestions on how to choose material


Lightweight and Soft Products:


If your products are relatively light and not prone to damage, a cardboard box can be a suitable option. Cardboard provides a cost-effective solution for packaging items like clothing, stationery, or non-fragile goods. This type of mailer box typically uses 180-350g/m² white cardboard, kraft paper, or white board paper.


Moderate Weight and Fragile Items:


For products that are a bit heavier or fragile, corrugated mailer boxes are the way to go. Corrugated cardboard consists of a fluted inner layer sandwiched between two linerboards, providing excellent strength and protection against impacts and compression.


The most commonly used types are three-layer B-flute, three-layer E-flute, and three-layer C-flute corrugated boards. Among these, the three-layer C-flute is thicker and softer, making it most suitable for the outer box of lightweight transport packaging to enhance cushioning and increase safety. On the other hand, E-flute boards are light, thin, and stiff, with relatively poor single-layer cushioning, making them ideal for packaging small items or even for art packaging purposes. They can be crafted into folding boxes to improve their cushioning performance. B-flute boards, positioned in terms of thickness and stiffness between C-flute and E-flute, offer versatility as they can be utilized both as primary packaging and as outer boxes.


Linerboard Weight:


The linerboard, which is the flat outer layer of corrugated cardboard, contributes to the box’s appearance and print quality. To maintain a professional and polished look, choose linerboard with a weight of over 140g. Lighter linerboard may allow the corrugated sheet’s ridges to show through, affecting the overall aesthetics. For varied packaging and transport requirements, selecting different thicknesses and types of linerboards is an option. These linerboards, enhanced through printing and post-press processing, can be adhered to corrugated paper to augment its thickness and stiffness. This enhancement not only provides additional structural support but also enriches the packaging design.


Custom Options


Size and Material


Recognizing the uniqueness of each product’s dimensions and protection needs, we provide the flexibility to select the ideal size for your mailer boxes. Whether it’s the robust corrugated cardboard for heightened security or the lightweight paperboard for cost-effective options, you have the freedom to choose the material that best aligns with your requirements.


Shape and Style


Give your mailer boxes a unique look with various shape and style options. Whether you prefer a traditional rectangular shape or a more unconventional design, we have the expertise to craft the perfect box that aligns with your brand aesthetics.


Imprinting Visuals


Imprinting your brand’s identity onto the mailer boxes is a pivotal part of the customization process. Our advanced printing capabilities ensure that your logo, imagery, and messaging are vividly showcased, leaving a lasting impression on recipients. Whether you opt for a minimalist design or a bold and intricate pattern, our high-quality printing ensures your vision comes to life with precision and clarity.


Other Creative Design Elements




In pursuit of an unparalleled unboxing experience, we present an array of innovative design elements that transform your mailer boxes into works of art:


Window Patch: Offer a tantalizing glimpse inside, generating excitement and anticipation as recipients catch a sneak peek of their awaited treasures.


Zippers: Fuse functionality with aesthetics by incorporating zippers that grant effortless access to contents while safeguarding items during transit.


QR Codes: Bridge the physical and digital realms by integrating QR codes, enabling interactive experiences that connect customers with your brand’s online presence.


Handle: Infuse practical elegance, offering both portability and aesthetic appeal, ensuring your mailer boxes are easy to carry while exuding sophistication. Sleeves: Elevate visual allure while enhancing protection with sleeves that encase your mailer boxes, providing an extra layer of safeguarding and branding opportunities.


Postpress Enhancements


To add a touch of elegance and sophistication, consider postpress enhancements. Options like spot UV coating, foil stamping, embossing, or glitter accents can elevate the visual appeal of your mailer boxes, making them truly eye-catching and memorable.


The post-printing enhancement process can often achieve more unique colors, gloss, and textures (such as UV coating, hot stamping, glitter, and laser treatments) or even three-dimensional relief effects on a flat surface (such as embossing and silk screening).


Techniques like lamination can enhance the appearance and protect the printing surface. Importantly, these processes can be combined on the same packaging, allowing designers more freedom, boldness, and precision in their creations. However, determining the best combination often requires the assistance of professional craftsmen.


Spot UV


UV coating is a widely used technique that adds a glossy, durable finish to printed materials. A clear liquid coating is applied and cured with ultraviolet light, providing protection against scratches, scuffs, and fading from environmental factors.


There are two main types of UV coating: clear UV, which highlights specific patterns with a glossy varnish, enhancing visual appeal, and colored UV, which directly applies colored varnish for vibrant and impactful designs, eliminating the need for background printing. Both options offer unique ways to enhance the look and durability of your printed products.


Foil Stamping


Delve into the intricate craft of foil stamping to infuse your items with texture, luminosity, and captivating aesthetics. The process encompasses two distinct methods: hot foil stamping and cold foil stamping. From a visual presentation standpoint, foil stamping offers a trifecta of choices: metallic, pigment, or holographic foil. Each variant contributes a unique and enchanting effect that elevates your packaging’s allure.


Beyond its aesthetic merits, foil stamping boasts remarkable resilience, successfully enduring variable climates and the test of time. Thus, your packaging exudes an enduring radiance that stands unwavering over prolonged periods.


Embossing & Debossing


Embossing and debossing techniques are artful ways to enhance packaging. Embossing lifts intricate designs from the surface, adding both visual and tactile intrigue, while debossing imparts subtle texture and refined elegance. These methods elevate your brand’s image, creating a touch of luxury that engages customers on multiple sensory levels.


Varieties of Embossing & Debossing


a) Blind Embossing/Debossing


Crafting intricate designs without additional color or foil, blind embossing and debossing create understated yet captivating visuals. Debossing gently presses patterns into the material, while embossing raises them, utilizing light and shadow to showcase texture and sophistication.


b) Registered Embossing/Debossing


By combining blind embossing with ink, foil, or other embossed elements, registered embossing captures attention with a dynamic 3D effect. This technique introduces color and texture into the equation, resulting in packaging that engages the senses and leaves a lasting impression.


Glitter Printing


Glitter printing stands out as a distinctive and specialized printing method that employs real metallic glitter particles infused into the ink, yielding a luminous and attention-grabbing outcome. This technique finds its versatility in its applicability to diverse surfaces such as paper and plastic substrates, rendering it an optimal selection for an array of applications, encompassing product labels, packaging boxes, as well as decorative elements like gift wrap and tissue paper. The myriad assortment of glitter particle sizes, colors, and shapes empowers product designers with the creative latitude to conceive genuinely distinctive and captivating designs, strategically engineered to captivate the gaze of potential customers amidst the expanse of store displays.


Common Applications Of Mailer box


Mailer boxes have become a retailer’s favorite for versatile applications like gift packaging and distributing promotional materials. Retailers leverage custom mailer boxes in subscription services, catering to a range of products from makeup to video games, offering customers an exceptional experience.


In addition to subscriptions, businesses rely on mailer boxes to dispatch items like books, catalogs, and merchandise for online orders, cementing their role in modern commerce.


The widespread dispatch of mailer boxes globally highlights their significant role and usage in the retail industry.


How to Cut Cost Of Mailer box


Increase Order Quantity:


As the saying goes, “buying in bulk saves money,” and this principle applies to mailer boxes too. Increasing the order quantity can lead to significant cost savings per unit.


Opt for Cost-Effective Materials:


Choosing cost-effective materials without sacrificing quality is another way to reduce expenses. For example, opting for clay-coated news back (CCNB) instead of solid bleached sulfate (SBS) may result in a slight reduction in glossiness but still maintains a satisfactory print quality.


Reduce Thickness:


While ensuring the safety of the packaged items, businesses can consider reducing the thickness of corrugated cardboard or the weight of linerboards. Careful testing and evaluation are essential to find the optimal balance between protection and cost.


Minimize Printing Colors:


Full-color printing can add significant costs to mailer boxes. By using a limited color palette or opting for spot colors, businesses can achieve visually appealing designs while keeping printing expenses in check.


The specifics of product packaging are intricate and complex, and cost reduction should be a primary consideration; the most suitable option is often the best. Therefore, it is essential to communicate thoroughly with craftsmen during the design process to achieve the desired outcome in terms of quality and cost.


Ways of payment


Full Payment for Small Orders:


For smaller orders with limited quantities, we require full payment at the time of purchase. This straightforward payment method ensures a smooth and efficient processing of your order.


Installment Payment for Large Orders:


We understand that larger orders may require more budget flexibility, and to better serve our customers, we offer the option of installment payments for bulk purchases. With this approach, you can spread the total cost of the order over multiple payments, making it more manageable and easing the financial burden.


Diverse Payment Methods:


We offer diverse payment methods to ensure convenience and cater to different preferences, including secure Company Checks, trusted PayPal for online transactions, and a range of Major Credit Cards like Mastercard, Visa, American Express, Discover, JCB, Maestro, and UnionPay, ensuring a seamless and efficient checkout process.


How are mailer boxes made?  




The first step in creating mailer boxes is printing. Regardless of the type of cardboard you choose, adding images and logos to the mailer boxes is essential for enhancing aesthetics and leaving a lasting impression on your customers. At our company, we utilize flexography printing for kraft cardboard and offset printing for white cardboard. These printing techniques, coupled with high-end equipment and advanced technology, ensure that your design is presented at its best, with vibrant colors and sharp details.


We utilize Heidelberg and Roland presses in a variety of sizes and colors to guarantee color accuracy, speed, flexibility, and reliability.


We take color accuracy seriously, and to achieve the perfect result, we conduct multiple rounds of color calibration and adjustments during the pre-production stage. This meticulous process ensures that your mailer boxes showcase your brand identity and design in the most striking and precise manner.


Additionally, if you desire specific visual enhancements like spot UV coating, glitter, or foil stamping, we carefully apply these finishing touches after printing to add a touch of elegance and sophistication to your packaging.




Composite the two pieces of brown or white cardboard and corrugated sheet into one piece with a strong adhesive. Flattened with a heavy object, they are kept from bending and deformation.


The composited cardboard have to experience about two-day natural drying in order to strengthen the cohesion between each other.




Die-cutting is a crucial step that determines the appearance and functionality of the mailer boxes. Custom shapes are precisely cut out using a die, which consists of sharp and blunt blades to mark edges and creases respectively.


Before mass production, our skilled technicians conduct multiple sampling inspections to ensure the die’s pressure is carefully calibrated. This prevents the cardboard from being overly pierced, reducing the risk of waste. Each step is thoroughly tested by our experts to ensure that every box is produced to perfection.


To maintain the highest quality standards, our machines undergo regular cleaning, ensuring that the finished products are free from defects like rough edges. Your mailer boxes will be flawlessly crafted to meet your specifications and exceed your expectations.


Box Cutting and Making


This is the last step and the most important one, boxes begin to take shape as offcuts are removed. The step seems simple, but that requires expertise since it directly affect the box making. We have our specialist equipment to do that. After that, the two-dimensional boxes are completed. If you prefer three-dimensional ones, just tell us without hesitation. Whether to receive unfolded boxes or finished ones depends on your requirement. 


Tips For your Mailer Box 




Oversized Boxes


Is bigger always better? One-size-fits-all policies can be problematic. Correct it before it’s too late. Oversized boxes are costly for businesses and inconvenient for customers. They can also lead to product damage during transit. Opt for the right fit to avoid these issues.


Here are common size options for various items that you can select based on your needs. If you’re uncertain about choosing the right size for your products, feel free to reach out to us for assistance.


9.2×9.2×5 cm

11.8×14×8 cm


Perfect for jewelry, cosmetics, or small accessories, these compact mailer boxes will enhance the value of your products.


32×18.9×9 cm

30.2×23.3×8.8 cm

35×26×10 cm


Medium-sized boxes are highly popular for clothing items like T-shirts, dresses, blouses, trousers, and light jackets, providing an ideal fit. 


44×33.9×15.9 cm

42.5×52×18 cm


For larger electronic appliances or heavy clothing items, our spacious mailer boxes offer the perfect match.


Complicated or inadequate packaging


Consider your customers’ feelings when they receive an item buried in excessive bubble-wrap and twist ties. Difficult-to-open packaging can lead to frustration and a negative experience. Moreover, excessive packaging generates unnecessary waste, which goes against the prevailing environmental protection culture. Embrace a positive corporate culture by adopting user-friendly and eco-friendly packaging solutions for your business growth.


Incorporating minimalism is a vital strategy to make your product shine. To effectively safeguard your product while adhering to a minimalist philosophy, using inserts is an optimal choice.


Wrong materials


Choosing the wrong materials for packaging is a common mistake among manufacturers. For example, kraft cardboard is not ideal for color-heavy images, resulting in muted prints. Additionally, using single-walled cardboard that is too thin can cause damage to the box and products. Proper material selection is essential for effective branding and product protection.




Branded boxes


Using branded boxes is a powerful way to enhance your packaging strategy. A well-designed branded box goes beyond mere packaging – it becomes an extension of your brand identity. Your company logo, colors, and design elements on the box can make a lasting impression on customers.


When they receive a package that bears your unique branding, it reinforces your brand’s professionalism and commitment to quality. Branded boxes not only contribute to a cohesive brand image but also create a sense of anticipation and excitement for what lies inside. This can lead to increased brand recognition and customer loyalty as your customers associate the positive unboxing experience with your brand.


Customer experience


The unboxing experience holds significant importance in today’s consumer-centric landscape. Customers cherish the excitement of unwrapping a package just as much as the product itself. To create a memorable and delightful unboxing experience:


Customized Inserts (Internal Supports): Tailor internal inserts to fit products snugly for sophistication and optimal protection during transit. This attention to detail demonstrates care for customers’ products and overall experience.


Colorful Fillers: Include vibrant fillers like tissue paper to heighten anticipation and surprise. These add elegance and whimsy to the unboxing process, evoking positive emotions as customers uncover their purchase.


Handles for Retail: Businesses in retail environments can enhance convenience by adding handles to mailer boxes. Easy carrying and organized stacking show thoughtfulness in the customer experience. Typically, a mailer box is rectangular. For products with irregular shapes, designing a suitable inner tray can prevent the product from shaking and being damaged inside the box. The choice of materials and structures for the inner tray is diverse and can be tailored to fit specific needs.




Quality Control


Q1: How do you ensure the quality of your mailer boxes?


A1: At our company, we take quality control seriously to deliver top-notch mailer boxes to our customers. Our quality assurance process includes various steps:


Professional Testing: We employ specialized testing equipment to conduct edge crush tests, adhesive strength tests, and other relevant evaluations to ensure the boxes’ strength and durability.


The Edge Crush Test (ECT) serves as an accurate performance assessment and has a direct correlation with the ability of a carton to withstand stacking pressures. ECT gauges the resistance of corrugated board to compression along its edges. The procedure involves compressing a small section of the board vertically between two solid plates, at a right angle to the flute direction, until a maximum load is reached. The result is quantified in pounds per inch of the load-bearing edge (lb/in), but it’s commonly presented as an ECT measurement


  Bursting Test Minimum Edge Crush Test Maximum Load Per Carton
Standard 200# 32 ECT 40 lbs.
Heavy Duty 275# 44 ECT 65 lbs.
Heavy Duty – Double Wall 275# 48 ECT 80 lbs.


External Verification: We also collaborate with reputable professional testing institutions, such as SGC (Sample Goods Certification), to validate our products’ adherence to industry standards and requirements. SGC is a globally recognized certification body that specializes in assessing and verifying product quality and safety.


Q2: Can I request a sample before placing a bulk order?


A2: Absolutely! We understand the importance of evaluating our products before making a substantial investment. We offer the option to request samples of mailer boxes so you can assess their design, material, and functionality firsthand. This way, you can be confident in your choice and make any necessary adjustments before placing a bulk order.





Q3: What is the typical lead time for receiving my order?


A3: The lead time for your order depends on several factors, such as the quantity, customization options, and shipping method selected. After receiving your order details, we will provide you with an estimated lead time. We work diligently to fulfill orders promptly, and our goal is to ensure you receive your mailer boxes within the agreed-upon timeframe.


Q4: Can you handle international shipping?


A4: Absolutely! We have experience in handling international shipments and can deliver mailer boxes to customers worldwide. Our logistics network is equipped to handle international shipping requirements, ensuring smooth and reliable delivery to your desired destination.


Other Aspects


Q1: Do you offer design services for custom mailer boxes?


A1: Absolutely! Our team of skilled designers is here to assist you in creating stunning and impactful designs for your mailer boxes. Whether you have a specific concept in mind or need guidance in developing a design that aligns with your brand, we are here to make your vision a reality.


Q2: What if I need to make changes to my order after it’s been placed?


A2: If you need to make changes to your order after it has been placed, please contact our customer support team as soon as possible. We will do our best to accommodate your request, but please note that changes may not always be possible depending on the production status of your order. We recommend reviewing your order details carefully before confirming to ensure accuracy.


Q3: Can I track my shipment?


A3: Yes, we provide tracking information for your shipment so you can monitor its progress and estimated delivery date. Once your order is dispatched, we will send you the tracking details, allowing you to stay informed about the status of your mailer boxes.



To conclude, the mailer box stands as the definitive solution for expertly and elegantly shipping your products. Beyond its durability and protective qualities, these adaptable and robust packaging wonders offer an avenue to display your brand and curate an unforgettable unboxing encounter for your clientele.


Consider this: Does your packaging truly reflect the value of your product? Have you explored the full potential of design and customization to resonate with your audience? The impact of packaging reaches far beyond the physical realm – it’s a gateway to customer connection and brand distinction. As you embark on this packaging journey, remember that every detail matters, and your choice can reshape perceptions and drive success. Will you let your packaging speak volumes about your dedication to quality and aesthetics? The power to captivate and enthrall awaits your innovative touch. Begin shaping a new chapter of packaging excellence and customer delight today! Contact us to start this journey of packaging excellence.



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