Mailer Boxes - Our most popular box style!
Strong and sturdy digitally printed mailer boxes made from corrugated cardboard. Perfect for shipping products by post or courier. Choice of suggested sizes or choose your own.
A mailer box is a popular type of packaging designed to store and send your products. Mailer boxes have interlocking flaps and wings, they are easy to assemble and they require no adhesive to be assembled and closed. They have double-thickness side walls which makes them extra durable when being transported compared to other types of corrugated cardboard packaging. The type of mailer boxes we offer are the FEFCO 0427 style and we use 1.5mm thick E-flute corrugated cardboard.
Our boxes are made from eco-friendly corrugated cardboard materials. For more information on the materials used, please see the 'Materials' tab above.
Whilst mailer boxes can hold themselves closed without any adhesive, when shipping the box by post or courier you will need to stick down the bottom of the front flap for extra security. Why not order a recycled paper sticker from us with your logo or design to seal your boxes? They're available in white or brown kraft recycled materials to compliment your boxes.
Our mailer boxes have the following benefits:
- Full colour, high resolution digital printing
- Eco-friendly materials
- Delivered flat-packed for easy self-assembly
- No setup or design fees
PLEASE NOTE: Mailer box materials are not suitable for direct contact with food. The flute direction may vary from box to box so that we can minimise the amount of waste material in our production process.
How to Fold Mailer Boxes
When we ship your boxes to you, they are sent flat-packed ready for easy self-assembly.
Step 1
One side of the flat box will have crease lines, this is the inside of the box. Place the box on a flat surface with this side facing up.
Step 2
Gently fold along all the creases for the side flaps and walls of the box. Do not fold along the creases with too much force and don't fold beyond 90 degrees.
Please Note: All mailer boxes will have double crease lines in two of their walls. It is very important that you fold along both sets of the two lines, or your box will not assemble correctly.
Step 3
Now you can start to build up the shape of your box. First, fold in the two pairs of side flaps as shown in the image below:
Step 4
Now fold the side walls (with the double crease lines) over the top of the side flaps and down into the slits in the bottom of the box as shown below:
Step 5
Now you can fold the rest of your box into this base. The side flaps should all fit inside the box and the final "wings" should fit into the sides at the front of the box to lock it shut.
Step 6
The box is now assembled and ready for you to fill with your contents!
Before sending the box in the post or with a courier, we recommend sealing the box shut with some tape or a sticker. Why not design your own sticker to seal your boxes and order them at the same time as your boxes? See our stickers product for an eco-friendly way to seal your boxes and promote your brand or message at the same time!
Technical Information
Printing
We digitally print using a high resolution 4 colour (CMYK) process to
print all logos, text and background colours.
Pantone® Colours
If Pantone® colours are used in your design we will use the CMYK
Pantone® matching system to print your design using CMYK inks. Please
note: There are many Pantone® colours that cannot be accurately matched
using CMYK colours. If you use a Pantone® colour that cannot be matched
it will be converted to the closest CMYK colour available.
Materials
E-flute (1.5mm thick - 440gsm) corrugated cardboard with a white colour on the outside and a brown kraft colour on the inside.
✅ Recyclable
✅ Recycled content (60-70%)
✅ Biodegradable
✅ Compostable
✅ Plastic-free
✅ Vegan-friendly
✅ Paper from responsible sources
E-flute (1.5mm thick - 440gsm) corrugated cardboard with a brown kraft colour on both sides.
✅ Recyclable
✅ Recycled content (60-70%)
✅ Biodegradable
✅ Compostable
✅ Plastic-free
✅ Vegan-friendly
✅ Paper from responsible sources
E-flute (1.5mm thick - 440gsm) corrugated cardboard with a brown kraft colour on the outside and a white colour on the inside.
✅ Recyclable
✅ Recycled content (60-70%)
✅ Biodegradable
✅ Compostable
✅ Plastic-free
✅ Vegan-friendly
✅ Paper from responsible sources
Product FAQs
- What sizes and dimensions are available for mailer boxes?
- We offer a range of 14 different "suggested sizes" for mailer boxes. These range from small boxes for sending jewellery and other small items, up to large boxes for shoes, jackets and electronics. Click on the "Order your mailer boxes now..." button to see our range of suggested sizes. You can also choose your own custom size mailer box if none of our suggested sizes work for you, but these are slightly more expensive.
- How are the mailer boxes supplied?
- Mailer boxes are supplied flat-packed ready for you to assemble. It's very simple... see the "Assembly" tab for a step-by-step guide.
- What are the options for printing the outside of a mailer box?
We have three options for printing the outside of your box when ordering:
- Design each side of the outside of your box separately (recommended)
- Repeat an image/logo multiple times across the entire outside of the box
- Upload one large image to be wrapped around the entire outside of the box
- What are the options for printing the inside of a mailer box?
For an additional cost, you can also design the inside of your box. We offer three options for printing the inside of your box:
- You can upload a repeating image or logo. This repeats across all inside sides of your box unless you chose a different design for the inside lid or inside bottom.
- You can design the inside lid of your box separately. The inside lid can have it's own design which will replace the repeating pattern (if chosen).
- You can design the inside bottom of your box separately. The bottom of your box on the inside can have it's own design which will replace the repeating pattern (if chosen).
You can choose any of these options individually, or even all three together, the choice is yours.- Do you offer plain (unprinted) boxes?
- Yes, we offer both printed and unprinted (plain) boxes. Simply follow our ordering process and choose the "Unprinted (plain)" option on the "Print" step.