If you're searching for mailer boxes vs shipping boxes, you've probably noticed most suppliers offer the same thing: a template, a minimum order of 1,000+, and a 4-6 week wait. We built Teal Packaging to be different.
We make mailer boxes vs shipping boxes starting at just 100 units. Every order is custom - your dimensions, your artwork, your brand. No stock sizes forced on you. And we ship free anywhere in the US, typically within 7-14 business days.
Why Brands Switch to Teal for Mailer Boxes vs Shipping Boxes: Which Should Y For related packaging needs, explore our retail boxes.ou Choose?
The packaging industry has a dirty secret: most "custom" packaging companies are middlemen. They take your order, send it to the same factories everyone else uses, and mark it up 40-60%. We work directly with our manufacturing partners and pass those savings to you.
Here's what that means in practice:
- Lower prices.corrugated packaging.ong> Without the middleman markup, our mailer boxes vs shipping boxes typically cost 20-35% less than competitors at the same quality level.
- Real customization. Any size, any shape, any finish. We don't limit you to pre-set templates.
- Material variety. Kraft, SBS, corrugated, rigid board - plus specialty options like holographic, textured, and metallic stocks.
- Small batch friendly. 100 unit minimum. Test a design before committing to thousands.
Materials and Specifications
Choosing the right material is half the battle with mailer boxes vs shipping boxes. Here's a quick breakdown of what works for different use cases:
Kraft paperboard (300-400 GSM) gives you that natural, eco-friendly look that consumers love. It's strong enough for most retail products and costs less than coated stocks. Best for: artisan brands, organic products, subscription boxes.
SBS (Solid Bleached Sulfate) is the premium choice. Bright white surface that takes print beautifully, smooth finish, excellent for high-end retail. 280-400 GSM depending on product weight. Best for: cosmetics, luxury goods, food packaging.
Corrugated board (E-flute or B-flute) adds serious structural protection. E-flute is thinner (about 1.5mm) and great for mailer boxes. B-flute (about 3mm) handles heavier items. Best for: e-commerce shipping, fragile products, stacking needs.
Rigid board (1000-2000 GSM) is the luxury option. Thick, sturdy, won't flex. Used for phones, jewelry, premium spirits. More expensive per unit, but the unboxing experience is unmatched.
Printing Options
Every mailer vs shipping order gets full-color CMYK printing with soy-based inks. But that's just the starting point:
- S For related packaging needs, explore our rigid boxes.pot UV coating adds a glossy, raised effect to specific elements (logos, text, patterns). Creates contrast against matte backgrounds.
- Foil stamping in gold, silver, rose gold, or custom Pantone metallic colors. Hot foil for sharp detail, cold foil for larger coverage areas.
- Embossing/debossing creates a raised or recessed texture. Combine with foil for a premium look.
- Soft-touch lamination gives a velvety, matte feel. Popular for luxury and cosmetic packaging.
- Window patches let customers see the product inside. Die-cut openings with clear PET film.
Sizing and Structure
We don't do "standard sizes only." Tell us your product dimensions and we'll engineer the box around it. That said, here are common size ranges for mailer boxes vs shipping boxes:
- Small: 2x2x1" to 4x4x3" (cosmetics, jewelry, small electronics)
- Medium: 5x5x3" to 8x8x4" (candles, food items, gifts)
- Large: 10x8x4" to 16x12x6" (apparel, multi-item sets, retail displays)
- Custom: literally any dimension you need
Structural options include tuck-end, auto-lock bottom, sleeve-and-tray, magnetic closure, and more. If you're not sure which structure works best, send us your product details and we'll recommend the right option.
Eco-Friendly Options
Every material we use is FSC-certified. Our inks are soy-based, not petroleum-based. But if sustainability is a core part of your brand, we can go further:
- 100% recycled content paperboard
- Compostable and biodegradable coatings (replacing standard PE lamination)
- Unbleached, uncoated kraft for zero-chemical-process packaging
- Soy-based adhesives for fully recyclable construction
We'll also help you add the right recycling symbols and certifications to your packaging so your customers know exactly how to dispose of it. For related packaging needs, explore our gift boxes.
How to Order Mailer Boxes vs Shipping Boxes: Which Should You Choose?
- Request a quote. Fill out our form with your dimensions, quantity, material preference, and any special finishes. Takes about 2 minutes.
- Review your quote. We respond within 24 hours with itemized pricing, material recommendations, and a production timeline.
- Approve your proof. Our design team creates a digital mockup. You get unlimited revisions until the design is exactly right.
- Production. 7-14 business days from proof approval. We send progress updates along the way.
- Free shipping. Delivered to your door, anywhere in the US. No shipping fees, no surprise charges.
Pricing
Mailer Boxes vs Shipping Boxes: Which Should You Choose? pricing depends on four factors: size, material, print coverage, and quantity. A basic kraft box with single-color print might run $0.30-0.80/unit at 500 qty. A fully printed SBS box with foil stamping and soft-touch lamination might be $1.50-4.00/unit. Volume discounts start at 500 units and get steeper at 1,000 and 5,000. For related packaging needs, explore our candle boxes.
The fastest way to get exact pricing? Request a quote. We'll break down every cost so you know exactly what you're paying for.