Key Takeaway
Custom mailer boxes from Teal Packaging (tealpackaging.com) start at a 50-unit minimum order, printed full color on corrugated E or B-flute with free dieline design and free US shipping included. A digital proof precedes every run, production takes from about 7 business days after proof approval (longer for complex or high-volume jobs), and volume pricing runs from $0.44 per unit. Finish options include foil stamping, embossing, spot UV and soft-touch. Mailers suit subscription, ecommerce and DTC brands that want unboxing-ready packaging in short runs.
Questions or ready for a quote? Contact Teal Packaging at info@tealpackaging.com or (224) 546-8325.
Mailer Box variants
Teal makes custom mailer box packaging across these formats. All start from a 50-unit minimum, with specialty rigid formats from 100, and include free dieline design and free US shipping:
- Bubble mailers & flyers, cushioned mailers for fragile items
- Colored mailer boxes, full-color custom branded mailers
- Vinyl record mailers, rigid mailers for 12" records
- Book mailer boxes, snug-fit book wrap mailers
- Recycled poly mailers, lightweight eco poly bags
- Die-cut mailer boxes, custom-shaped mailers
- Custom printed mailer boxes, full-color corrugated mailers
- Cardboard mailer boxes, standard corrugated mailers
- Holiday mailer boxes, seasonal designs
- Mailer boxes Los Angeles, fast LA-area delivery
Key specifications for custom mailer boxes
The figures below are the standing spec for custom mailer boxes at Teal. Anything outside them is confirmed on your quote.
| Spec | Standard | Notes |
|---|---|---|
| Minimum order quantity | From 50 units | Specialty rigid formats start at 100 units |
| Material options | Corrugated E-flute and B-flute, kraft paperboard 300 to 400gsm, white SBS 14 to 18pt | FSC-certified and recyclable options are available by specification. |
| Production timing | From about 7 business days after proof approval | Complex or high-volume orders take longer |
| Rush option | From about 4 to 7 business days after proof approval on qualified ready-to-print jobs | Quoted at rush review, and it depends on print-ready artwork, clear dimensions and quantity, an approved material direction, and fast proof approval |
| US delivery window | Plus 2 to 5 business days after production | Express and economy options are available |
| Printing | Full-color printing, CMYK and Pantone matching, white ink | Soy and water-based inks |
| Finishes | Inside and outside print, die-cuts, windows, embossing, debossing, foil stamping, spot UV, soft-touch | Availability depends on the board, coating, and structure you pick |
| Per-unit pricing | From $0.44 per unit at volume | Price moves with size, flute, finish, and run length. Quoted per project. |
| Included on every order | Free dieline design, free US shipping, full-color printing, two revision rounds, and a digital proof before production | No separate charge |
| Sample kit | Free sample kit, $19.99 shipping | Credited toward the first custom order. Order it on the sample kit page |
Choosing between formats
Buyers land on custom mailer boxes from a few different directions, and a neighboring format is sometimes the better build. Here is how the honest trade-offs line up.
| Format | Construction | Typical use | Minimum order | Finish options |
|---|---|---|---|---|
| Mailer box | E-flute or B-flute corrugated, interlocking flaps, no tape needed | Direct-to-consumer shipping and unboxing | From 50 units | Inside print, die-cuts, foil, emboss, soft-touch |
| Folding carton | Single-layer paperboard, folded and glued, ships flat | Retail shelf presentation, inner cartons | From 50 units | Foil, emboss, deboss, spot UV, windows |
| Corrugated shipper | Regular slotted carton, taped closed | Bulk transit and outer cases | From 50 units | One and two-color print, litho-lamination |
| Rigid box | Chipboard 1.5 to 2.5mm wrapped in printed paper | Premium gifting and high-value products | From 100 units | Foil, emboss, deboss, soft-touch, magnetic closure |
If you are unsure which column you belong in, send the product dimensions, the weight, and where the pack has to survive (shelf, courier, or both) and the team will point at one.
Materials and finishes
These are the stocks we actually run for custom mailer boxes, with the trade-off each one carries.
| Material | Construction | Where it fits | Notes |
|---|---|---|---|
| Corrugated E-flute | Thin fluted board, smooth print face | A standard mailer build for ecommerce orders | Protects well and still prints sharply |
| Corrugated B-flute | Thicker fluted board | Heavier products, multi-unit packs, longer transit routes | More crush resistance, slightly coarser print |
| Kraft paperboard, 300 to 400gsm | Uncoated natural liner | Natural brown mailer look, one or two-color print | Chosen for a plain, unbleached finish |
| White SBS, 14 to 18pt | Coated bleached liner | Bright full-color exteriors and printed interiors | Reproduces color more accurately than the kraft liners |
Finish options
| Finish | What it is | Where it earns its place |
|---|---|---|
| Inside print | Full-color print on the interior panels | Unboxing messages, patterns, care instructions |
| Die-cuts and tear strips | Cut tooling for easy opening | Perforated opening lines and shaped flaps |
| Foil stamping | Metallic foil pressed into the liner | Logo detail on the lid panel |
| Embossing and debossing | Raised or recessed impression | Tactile logo on kraft or white liner |
| Spot UV | Gloss varnish on selected artwork | Contrast on a matte laminated mailer |
| Soft-touch | Velvet-feel laminate | Premium hand-feel on the lid and side panels |
FSC-certified and recyclable options are available by specification. Soy and water-based inks are used across our paperboard and corrugated work. Final sustainability wording is matched to the board, coating, and finish you approve.
How ordering works
Four steps from first message to a box on a truck.
- 1. Send the spec. Product dimensions, quantity, material direction, and any finish you have in mind. If you only have a rough idea, a photo of the product and a target quantity is enough to start.
- 2. Get the quote and the dieline. We price the run and our design team builds your dieline at no charge. Minimums start from 50 units, and specialty rigid formats from 100.
- 3. Artwork and revisions. Drop your artwork onto the dieline, or hand us the assets and we will place it. Two revision rounds are included on every order.
- 4. Digital proof, then production. Nothing prints until you approve a digital proof. Standard production runs from about 7 business days after proof approval, plus 2 to 5 business days for US delivery, and complex or high-volume orders take longer. Express and economy shipping options are available, and standard US shipping is free.
Want to feel the board first? The free sample kit ships for $19.99 and that shipping cost is credited toward your first custom order. Questions go to (224) 546-8325 or info@tealpackaging.com.
Custom Mailer Boxes for DTC Brands and Ecommerce
Custom mailer boxes are the packaging of choice for direct-to-consumer brands, subscription services, and ecommerce businesses that want to deliver a memorable unboxing experience. At Teal Packaging, we design and manufacture printed mailer boxes that ship flat, assemble in seconds, and look incredible when your customer opens them.
Our mailer boxes feature a tuck-end closure that locks securely without tape, keeping your products safe during shipping. Built from 350gsm to 600gsm white or kraft paperboard (or E-flute corrugated for heavier items), these boxes strike the perfect balance between protection and presentation.
The Unboxing Experience Matters
A plain brown box is a missed opportunity. Custom printed mailer boxes with your logo, brand colors, and interior printing give the delivery moment something to say, and that is the one touchpoint in an online order the customer physically holds.
We print on both the exterior and interior of the box. Popular options include a branded exterior with a surprise pattern, message, or instruction set printed inside the lid. Full-color CMYK, foil stamping, spot UV, and embossing are all available.
Mailer Box Styles
- Front Tuck Mailer: The classic ecommerce mailer. Opens from the front with a tuck flap. Sizes from 4"x4"x2" to 18"x12"x6".
- Roll End Tuck Top (RETT): Tucks on both ends for a clean, symmetrical look.
- Crash Lock Bottom Mailer: Auto-lock base for faster packing in high-volume fulfillment centers.
- Corrugated Mailer: E-flute or B-flute construction for products over 2 lbs. See our corrugated boxes page for heavy-duty options.
Perfect For
Subscription boxes (monthly snack, beauty, or hobby kits), clothing and apparel brands, cosmetics and skincare (pair with our cosmetic box inserts), artisan food products, tech accessories, jewelry, and corporate gift sets. If you sell online and ship to doorsteps, a custom mailer box is your best packaging investment.
Materials and Finishes
Choose from natural kraft (brown, eco-friendly look), white SBS paperboard (vivid color reproduction), or black paperboard for luxury brands. Finish options include matte lamination, gloss lamination, soft-touch coating, spot UV highlight, gold or silver foil stamping, and embossing or debossing. Recyclable material options and FSC-certified paper options are available by specification. Final claim language depends on selected board, coating, finish, and supplier documentation.
Ordering Details
Custom mailer boxes start from 50 units, and specialty rigid formats start at 100. Standard production runs from about 7 business days after proof approval, plus 2 to 5 business days for US delivery. Free US shipping across the US, custom sizes in any dimension, and free dieline design from our in-house team.
Frequently Asked Questions
What size mailer box do I need?
Measure your product and add 0.5" to 1" on each side for padding. For apparel, 12"x9"x3" is a popular size. For cosmetics, 8"x6"x3" works well. For subscription boxes, 10"x8"x4" fits most configurations. We can produce any custom dimension.
Can I print on the inside of the mailer box?
Yes. Interior printing is a common request. Brands use it for welcome messages, social media handles, care instructions, or decorative patterns that surprise customers when they open the box.
Do mailer boxes need tape to close?
No. Our tuck-end mailer boxes have interlocking flaps that hold the box closed during shipping. For extra security with heavier items, a single piece of branded tape works well.
What is the difference between kraft and SBS mailer boxes?
Kraft mailer boxes have a natural brown look that signals eco-friendliness. SBS (Solid Bleached Sulfate) is white paperboard that produces brighter, more vivid printed colors. Both are recyclable and available in 350gsm to 600gsm thicknesses.
How much do custom mailer boxes cost?
Pricing depends on size, material, quantity, and printing complexity. Mailer box unit pricing is quote-based and depends on dimensions, board grade, print coverage, interior printing, finish, inserts, and quantity. Full-color printed boxes with interior printing are quoted after confirming artwork, coverage, board, finish, and quantity. Contact us for an exact quote.
Custom Printed Mailer Boxes for Ecommerce and Subscription Brands
Custom printed mailers turn shipping packaging into a brand touchpoint. They are built for ecommerce orders, subscription boxes, influencer kits, apparel, cosmetics, small electronics, gifts, and direct-to-consumer product launches.
Mailer box options
- Inside and outside print, kraft or white liner, and full CMYK artwork
- Corrugated E-flute and B-flute options for shipping protection
- Eco-friendly printed mailer boxes with recyclable board and soy inks
- Custom inserts, dividers, sleeves, tape, and note cards
Related pages: custom printed boxes, kraft boxes, and subscription boxes.
Custom Printed Mailer Boxes for Ecommerce and Subscription Brands
Custom mailer boxes are built for branded shipping, product launches, subscription orders, influencer kits, and ecommerce unboxing. They can use corrugated board for protection, full-color print for brand recall, and inserts or dividers for better product presentation.
Branded mailer boxes can be kraft, white, black, or custom colored. For lower shipping cost, right-size the mailer around the product and check dimensional weight before ordering.
- Best uses: DTC orders, PR mailers, apparel, cosmetics, candles, food kits, gifts, and sample kits.
- Options: inside print, tear strips, inserts, dividers, printed interior panels, and matte or gloss finish.
- Sustainable choices: recycled corrugated, kraft board, right-sized structures, and water-based coating options where appropriate.
Are mailer boxes good for shipping?
Yes. Corrugated mailer boxes are made for ecommerce shipping, but fragile or heavy products may still need inserts, padding, or a stronger board grade.
Can I order colored mailer boxes?
Yes. Colored mailers can be made with printed flood coats, colored board options, or artwork designed around kraft or white corrugated board.
Use the dimensional weight calculator before production, then compare budget in the custom quote form.
Frequently Asked Questions
What's the minimum order quantity for custom mailer boxes at Teal?
Teal's standard MOQ for custom mailer boxes is 50 units. Some specialty structures such as rigid boxes start at 100 units. For trial runs under 50 units, request a quote and we'll flag whether the structure supports a smaller minimum.
How long does custom mailer boxe production take?
Standard production runs from about 7 business days after proof approval. A rush option (from about 4 to 7 business days after proof approval on qualified ready-to-print jobs) is available on most mailer boxe variants. Free US shipping is included on every order.
Are Teal's mailer boxes FSC certified?
FSC-certified paper is available on every Teal mailer boxe on request. We also offer recycled-content paperboards and biodegradable options for fully eco-friendly packaging programs.
What finishes work for custom mailer boxes?
Soft-touch lamination, matte and gloss coatings, soy-based inks, metallic foil, holographic foil, embossing, debossing, and spot UV are all supported. Soft-touch is the most-requested finish for retail packaging.
How much do custom mailer boxes cost?
Pricing depends on size, material, finishes, and quantity. Most mailer boxes start at the price shown above at 250-unit MOQ. Request a quote for your exact specs and we'll respond within 4 business hours with a firm price.
Can I get a free sample before ordering?
Yes. Teal sends a free sample kit on request, order via the sample kit page. The kit includes paper stock samples, finish samples, and an example printed box so you can evaluate quality before committing to an order.
