Custom Mailer Box Solutions Built for Modern E-Commerce Brands
Your packaging is the first physical touchpoint your customer has with your brand. A well-designed custom mailer box does not just protect what is inside - it communicates who you are before the product is even revealed. At Teal Packaging, we help e-commerce brands, subscription services. And direct-to-consumer businesses create mailer boxes that turn every delivery into a brand moment.
Our custom mailer box production is handled through trusted manufacturing partners who meet our strict quality and sustainability standards.
We offer a minimum order quantity of 50 units with Free shipping is included on every Teal order, with delivery details confirmed during quoting.
Our standard production turnaround is two weeks, and every order comes with access to free design support to ensure your artwork looks exactly right before a single box is printed.
Materials and Construction for a Custom Mailer Box
The performance of a custom mailer box depends on the board quality and construction method. Here is what we use:
- Single-wall corrugated board: B-flute (3mm) or E-flute (1.5mm) for lightweight, cost-efficient mailer boxes suited to most e-commerce shipments
- Double-wall corrugated board: BC-flute (6mm) for heavier or more fragile products requiring additional crush resistance
- Rigid board mailers: 1200 gsm to 1800 gsm chipboard for flat, book-style mailers used for apparel, accessories, and premium products
- Exterior print surface: Coated kraft liner in 140 gsm to 200 gsm for vivid full-color printing directly on the corrugated structure
- Interior liner options: Natural kraft, white coated, or custom printed interiors available to complete the unboxing presentation
All board stocks are selected for their combination of structural performance during transit and printability for brand graphics.
Customization Options for Your Mailer Box
A custom mailer box from Teal Packaging is built to your exact specifications from the inside out:
- Printing: Full-color CMYK print on exterior, interior, or both. Spot colors available for Pantone-accurate brand elements.
- Closure types: Auto-lock bottom with tuck-top lid, self-locking closure (no tape required), tear-strip opening, and press-lock styles
- Finish options: Matte lamination, gloss lamination, and soft-touch lamination on the exterior print panel for added durability and premium appearance
- Add-ons: Perforated tear strips, custom tissue paper inserts, branded tape, and compartment dividers
- Custom dielines: Non-standard configurations including partitioned interiors and two-piece mailer sets available upon request
Our free design support team will help you lay out your artwork on the correct dieline, check bleed areas, and ensure your print file is ready for production without costly revisions.
Available Sizes for Custom Mailer Boxes
We offer a broad range of mailer box sizes to accommodate products of all shapes and weights. Common sizes include:
- Extra small: 6 x 4 x 2 inches - perfect for jewelry, small accessories, and sample products
- Small: 8 x 6 x 4 inches - popular for cosmetics, single-item apparel, and skincare products
- Medium: 10 x 8 x 4 inches - versatile size for multi-item orders, books, and mid-size product ranges
- Large: 14 x 10 x 4 inches - suited for subscription box programs, apparel, and larger retail items
- Extra large: 18 x 14 x 6 inches - designed for bulky goods, bundled sets, and high-volume subscription shipments
- Fully custom: Any interior dimension can be produced to your specifications
Choosing the right box size minimizes void fill, reduces dimensional weight charges from carriers, and ensures your product arrives without damage or excessive movement inside the box.
Our Commitment to Sustainable Mailer Box Production
Teal Packaging takes sustainability seriously across every product we offer.
Our custom mailer boxes are produced using FSC-certified corrugated board sourced from responsibly managed forests, ensuring your packaging meets the expectations of environmentally conscious consumers. We print using soy-based inks. Which deliver richer color saturation, are biodegradable. And make the board easier to recycle at end of life.
Our mailer boxes are curbside recyclable in most markets. And we can produce them in fully compostable configurations for brands with the most demanding eco-credentials. Sustainable packaging is not just a marketing claim for us - it is built into the materials and processes our manufacturing partners use every day. Pair your mailer boxes with our kraft boxes and retail boxes for a cohesive, planet-friendly packaging lineup.
How to Order Your Custom Mailer Box
The ordering process is designed to be fast, transparent, and stress-free:
- Step 1 - Share your specs: Tell us your interior dimensions, flute type preference, quantity, print coverage, and finish requirements.
- Step 2 - Get a quote: We provide a clear, itemized quote. No hidden fees. Minimum 50 units.
- Step 3 - Artwork and dieline: Our free design team provides your dieline template and reviews your artwork for print readiness.
- Step 4 - Proof and approve: Approve your digital proof before production starts. Turnaround begins from proof sign-off.
- Step 5 - Production and shipping: Two-week production followed by Free shipping is included on every Teal order, with delivery details confirmed during quoting.
Need something more specialized? Explore our mailer boxes collection, subscription boxes, or gift boxes for additional configurations and formats suited to your products.
Frequently Asked Questions About Custom Mailer Boxes
What is the minimum order for a branded mailer box?
The minimum order quantity is 50 units per size. This low MOQ makes professional branded mailer boxes accessible to startups, small brands, and businesses trialing a new packaging design before scaling up to higher volumes.
Can I print on the inside of the mailer box?
Yes. Interior printing is a popular option that transforms the unboxing experience. You can print a branded pattern, a thank-you message, care instructions. Or promotional content on the interior walls and base of your mailer box. Interior printing is available in single-color and full-color CMYK options.
Do custom mailer boxes require tape to close?
Many of our mailer box styles feature self-locking closures that do not require tape. Auto-lock bottoms and press-lock lids secure without adhesive. Which speeds up your packing line and creates a cleaner presentation. Tear-strip options can also be added to provide tamper-evidence without additional tape.
What board thickness do I need for my products?
For most lightweight e-commerce shipments under 5 lbs, E-flute corrugated board provides excellent protection with a slim profile. For heavier or more fragile items, B-flute or double-wall BC-flute provides greater crush resistance.
Our team will recommend the right board spec based on your product weight, fragility, and shipping conditions during the quoting process.
Can I request a physical sample before placing my full order?
Yes. Physical pre-production samples are available and strongly recommended for first-time orders or complex configurations. Sample lead times vary, so contact our team early in the process if a physical proof is important to your approval workflow. Digital proofs are included as standard for all orders.
