Mailer Boxes Guide: Everything You Need to Know
Mailer boxes are the default packaging choice for ecommerce brands, subscription services, and direct-to-consumer products. They are designed to ship without an outer shipping box, saving material and cost while maximizing branding opportunity. This guide covers box styles, materials, sizing, and design best practices.
Mailer Box Styles
Tuck-Top Mailer Boxes (Roll-End Tuck-Top)
The most popular mailer box format. The lid tucks into the front wall of the box, creating a clean closure. Easy to assemble, pack, and seal. Ideal for most ecommerce products, clothing, cosmetics, and food items. Available with or without a dust flap.
Roll-End Front Tuck (REFT)
Similar to the tuck-top but with the opening on the front face instead of the top. Creates a different unboxing angle that can be more dramatic for product presentation. Common for gift boxes and premium product packaging.
Full-Overlap Mailer
Both top and bottom panels overlap completely, creating double-thickness on all sides. Maximum protection for heavy or fragile items. Slightly higher material cost but worth it for products over 5 lbs or items prone to damage.
Crash-Lock Bottom Mailer
The bottom of the box snaps together automatically when opened (no tape needed for the bottom). Speeds up packing on fulfillment lines. The top uses a standard tuck closure. Ideal for high-volume operations where packing speed matters.
Corrugated vs. Cardboard Mailers
Corrugated Mailers (E-Flute or B-Flute)
Corrugated mailer boxes have a fluted inner layer that provides cushioning and structural strength. E-flute (1.6mm thick) is the standard for most mailer boxes. It offers good protection with a smooth surface for high-quality printing. B-flute (3.2mm thick) adds more cushioning for heavier items.
- Better protection during shipping
- Can handle products up to 10-15 lbs without additional padding
- Good print quality on E-flute surfaces
- Standard choice for ecommerce and subscription boxes
Folding Carton (Paperboard) Mailers
Made from solid paperboard (typically 350-400gsm), folding carton mailers are thinner and lighter than corrugated. They offer excellent print quality (comparable to retail packaging) but less crush protection. Best for lightweight items like cosmetics, jewelry, and small accessories.
- Superior print quality and finishing options
- Lighter weight reduces shipping cost
- Less protection than corrugated, needs inner padding for fragile items
- Premium feel and appearance
Sizing Your Mailer Box
Oversized mailer boxes waste material, increase shipping costs (dimensional weight), and require more void fill. Undersized boxes risk product damage and make packing difficult.
Optimal sizing formula:
- Length: Product length + 0.5 inches clearance
- Width: Product width + 0.5 inches clearance
- Height: Product height + 0.25-0.5 inches (account for any insert or padding)
If you ship multiple products in the same box, size for your most common assortment rather than your largest possible order. Use void fill for smaller orders.
Printing Inside and Outside
Exterior Printing
Full-color exterior printing turns your mailer box into a brand touchpoint on every doorstep. Standard options include CMYK full-color, Pantone spot colors, and single-color printing. White ink printing on kraft boxes creates a distinctive natural look.
Interior Printing
Printing the inside of the lid and base creates a surprise element during unboxing. Use the interior for a welcome message, product usage tips, social media handles, or a decorative pattern. Interior printing adds 15-25% to the per-unit cost but significantly increases social media shareability.
Inserts and Accessories
- Cardboard inserts: Die-cut dividers that hold products in place. Fully recyclable, cost-effective, custom-shaped to your products.
- Foam inserts: EVA or polyurethane foam die-cut to product shape. Maximum protection for glass, electronics, and fragile items.
- Tissue paper: Wraps products for presentation and light protection. Available custom-printed with your brand.
- Thank-you cards: Printed insert cards for messaging, discount codes, or care instructions.
- Custom stickers: Seal tissue paper or bags with a branded sticker. Low cost, high impact.
Order Custom Mailer Boxes
Teal Packaging produces custom mailer boxes in any size, any material, with full-color printing inside and out. No minimum order quantity, 7-day production, free shipping to US, Canada, UK, and Australia. All materials are FSC-certified and printed with soy-based inks.
Tell us your product dimensions and quantity, and we will send you a custom quote with dieline, material recommendation, and pricing within 24 hours.
