Custom Kraft Mailer Boxes Built for Brands That Ship
If your business ships products directly to customers, the mailer box is the first physical touchpoint your brand has with a buyer. Custom kraft mailer boxes strike the right balance between rustic, natural character and the structural performance required for e-commerce shipping. Unlike plain brown corrugated boxes, kraft mailer packaging carries warmth and personality that instantly communicates a brand with intention. Teal Packaging works with experienced manufacturing partners to produce custom printed kraft mailer boxes for brands across retail, subscription, food, cosmetics, and lifestyle categories. With free shipping to the US, Canada, UK, and Australia, a two-week turnaround, and a minimum of just 50 units, we make premium mailer packaging accessible at any stage of your growth.
Materials and GSM Options for Kraft Mailer Boxes
The structural quality of a mailer box depends heavily on the board weight selected. Custom kraft mailer boxes are available in several material configurations to match your product weight, fragility, and shipping method:
- E-flute corrugated kraft: A lightweight corrugated option offering excellent rigidity and crush resistance, ideal for products up to approximately 2 lbs. The E-flute profile is thin enough to allow high-quality printing on the outer surface.
- B-flute corrugated kraft: Heavier duty than E-flute, recommended for products between 2 and 10 lbs or items requiring extra padding from the corrugated structure.
- 300 gsm solid kraft board: Used for rigid-style mailer boxes without a flute layer. Suitable for lightweight items such as apparel, accessories, and stationery that need structure but not corrugated cushioning.
- 350 gsm solid kraft board: Premium-weight board for luxury mailer applications where an exceptionally firm, weighty box signals quality to the recipient.
All board options are available in natural unbleached kraft, which provides a distinctive earthy tone ideal for printing with soy-based inks. Manufacturing partners print to tight color tolerances on all kraft surfaces.
Customization Options for Your Kraft Mailer Box
Custom kraft mailer boxes are fully customizable inside and out. The exterior is your brand's canvas and the interior is an opportunity to deepen the unboxing experience. Options include:
- Exterior printing: Full-color CMYK, single or two-color spot printing, or white ink printing for bold contrast against the kraft base.
- Interior printing: Brand patterns, thank-you messages, social media handles, or care instructions printed on the inside of the box lid or base.
- Finishes: Matte lamination, spot UV, aqueous coating, or natural uncoated kraft.
- Closure style: Self-locking tuck (no tape needed), magnetic closure, or press-fit rigid lid depending on the box construction type.
- Custom sizing: All dimensions are fully adjustable to fit your product footprint precisely, reducing internal movement and excess void fill.
- Tissue paper and inserts: Kraft or colored tissue paper, branded shredded fill, and custom foam or cardboard inserts are available as add-ons.
Every order includes free design support. Our team will review your files, advise on print feasibility, and issue a digital proof before production begins.
Standard Sizes for Custom Kraft Mailer Boxes (Inches)
The following standard sizes cover the most common e-commerce shipping needs. All sizes can be modified to custom dimensions:
- Small: 6 x 4 x 2 inches - ideal for jewelry, small accessories, and sample kits
- Medium: 10 x 8 x 4 inches - suits folded apparel, skincare sets, and candles
- Large: 14 x 10 x 4 inches - handles books, multi-item gift sets, and larger lifestyle products
- Extra-large: 18 x 12 x 6 inches - suited for bulkier soft goods, shoes, or curated subscription boxes
- Square: 8 x 8 x 4 inches - popular for food gifting, floral, and symmetrically packaged product sets
For subscription products, view our custom subscription boxes for mailer options engineered for monthly recurring shipments. For gifting applications, our custom gift boxes provide elegant alternatives suited to premium retail and direct-to-consumer gifting.
Sustainability Features of Kraft Mailer Boxes
Kraft is inherently one of the most sustainable packaging materials available. When you order custom kraft mailer boxes from Teal Packaging, sustainability is built into every stage of production: For related packaging needs, explore our vape packaging.
- FSC-certified board: All kraft board is sourced through Forest Stewardship Council-certified supply chains, guaranteeing responsible forest management from tree to box.
- Soy-based inks: Low-VOC, plant-derived inks that produce vivid print results and simplify downstream paper recycling.
- Recyclable and compostable: Kraft board is fully recyclable curbside and compostable in commercial compost facilities.
- Right-sized packaging: Custom sizing means less void fill, fewer secondary packaging materials, and lower dimensional weight charges from carriers.
Explore our full range of custom mailer boxes to compare kraft, corrugated, and rigid mailer configurations side by side.
How to Order Custom Kraft Mailer Boxes
Getting your custom mailer boxes into production is a clear, well-supported process at Teal Packaging:
- Request a quote: Use the on-page form to submit your dimensions, quantity, and any special requirements. Responses arrive within one business day.
- Design and proofing: Share your artwork or work with our free design team to create it. You receive a full-color digital proof to approve before production begins.
- Production: Approved orders move into production with a two-week standard turnaround.
- Delivery: Finished boxes ship free to addresses in the US, Canada, UK, and Australia. Tracking is provided at the time of dispatch.
The minimum order is 50 units. Volume pricing is available for larger runs, and repeat orders benefit from stored dieline files for faster reordering.
Frequently Asked Questions About Custom Kraft Mailer Boxes
What is the difference between a mailer box and a shipping box?
A mailer box is a self-closing box designed to be shipped without an outer shipping carton. It typically features a tuck-close or magnetic lid and is built to withstand transit on its own. A shipping box is usually a plain corrugated carton used as an outer protective layer. bespoke kraft mailer boxes serve both functions at once: they are presentable for the customer and structurally robust for the carrier.
Can the inside of the mailer box be printed?
Yes. Interior printing is one of the most effective ways to extend the unboxing experience. Common interior print elements include brand patterns, thank-you messages, discount codes for repeat purchases, and social media handles encouraging customers to share their unboxing. For related packaging needs, explore our corrugated packaging.
Are kraft mailer boxes recyclable?
Yes. Natural kraft board is accepted in standard curbside paper and cardboard recycling. If you choose a matte lamination finish, the laminate layer can reduce recyclability. For maximum recyclability, we recommend the natural uncoated kraft finish or aqueous coating, which is more compatible with paper recycling streams.
How many units is the minimum order?
The minimum order quantity is 50 units. This makes it possible for small businesses, startups, and independent brands to access fully custom printed mailer boxes without committing to warehouse-scale quantities upfront.
Can I reorder without redesigning my boxes?
Yes. Once your dieline and approved artwork are on file, reorders can be placed quickly without going through the full design cycle again. The stored files ensure color and structural consistency across all production runs.