Custom Mailer Packaging Boxes Wholesale

Get Quote

Name *

Email *

Phone Number *

Zip Code *

Length *

Depth *

Width *

Units *

Product Name *

Select Material

Quantity *

Card Thickness

Color Options

Turn Around Time

Upload Your Artwork (PNG, PDF, JPG, JPEG Max File Size 5MB)

Message

In Stock

Custom Mailer Boxes

In Stock

Custom Mailer With Zipper

In Stock

Custom Rigid Mailers

The rise of online shopping started in the mid-1990s. And this behavior of buying items remains a favourite consideration for most buyers today. Now, global e-commerce is worth roughly $39 trillion. This is obvious because everyone prioritises their comfort first and searches for the item they are looking for.

E-commerce is a business model where you never have to go anywhere, and the product is available to the client on a mobile screen. This is a major reason why this industry has seen rapid growth in the past few years. And the major contribution behind it is custom mailer packaging. They are durable containers that not only ensure safe deliveries but also promote the brand effectively.

Explore this guide below to learn the manufacturing steps involved in the production of these boxes.

What Is Mailer Packaging?

Pre-glued packaging design for shipping products directly to the customer’s doorstep. Custom postal packaging is shipped flat and doesn’t require tape for assembly, which reduces the time to deliver a large number of parcels. They are lightweight but experts at providing enough cushioning needed to keep the items in original condition.

Brands can add their company logo and information essential for the customer to make future purchase decisions. Here are some of their highlighted features you have to take a look at.

Feature	Material Substrate	Ink Formulation	Closure System
Standard	Kraft Corrugated (E/B Flute)	Water-Based / Flexo Inks	Standard Tuck Flap + Shipping Tape
Mid-Tier E-Commerce	White Bleached Board / SBS	Soy-Based CMYK Inks	Tab-Lock Box
Premium Tier	High-Caliper SBS + Lamination	UV-Cured / Match Pantone (PMS)	Integrated Dual Peel-and-Seal Strips

Following the styles common in personalised mailer boxes.

Style	Structure & Mechanism	Best Uses
Custom Rigid Mailer	Designed to protect items from creasing, folding, or bending and keep them in a flat posture.	Stationery, Magazines, Books, Photography
Full Overlap Mailer	These boxes have extended flaps that cover the top and bottom to the edges when closed.	Subscription Boxes, Ceramics, Glassware, Hardware Parts
Front Lock Mailer	Features extended locking tabs that tuck into the die-cut slots of the front panel.	Apparel, Soft Goods, Influencer, PR Unboxing Packages
Roll End with Locking Cover	Comes with the additional rolled side panel that tabs into the tray without the use of any glue or tape.	Gift Kits, Influencer PR, Cosmetics & Skincare, Gadgets
Roll End Tuck Front (RETF)	Assemble effort without requiring any adhesives; have rolled side walls that tuck into the body.	Retail-Ready Edibles, Promotional Packages, Beauty Kits
Standard Tuck Top Mailer	Equipped with a single front closure flap to ensure the boxes will remain closed throughout shipping.	Subscription Services, Accessories, Clothing

Matchless Durability with Sturdy Stocks

The core purpose of any packaging is to deliver the product with ultimate protection; if it fails to fulfil this intent, this would be faulty packaging. To prevent the items from catching damage, the material is responsible. This is the outer section of the packaging that faces high pressure and drop impact during transit.

So, the material shouldn’t be collapsed for ensuring the successful delivery. Because the less you face returns, the more you can focus on your brand growth. The corrugated sheets are used for making custom packaging mailer boxes. They are a combination of multiple sheets acting as a shock absorber to avoid damage. Here are the stocks used in the making of custom mailer boxes.

Corrugated Cardboard

Consists of two outer flat sheets; between them, a fluted layer is sandwiched, which is responsible for absorbing the impact of shock caused by drops or handling. The material has further subtypes that are used for the production of custom mailing boxes.

Flute Type	E-Flute	F-Flute	B-Flute	C-Flute	A-Flute
Thickness	1/16 inch (1.5 mm)	1/32 inch (0.8 mm)	1/8 inch (3.0 mm)	3/16 inch (4.7 mm)	1/4 inch (6.4 mm)
Best Used For	E-Commerce Mailers, Shelf-Ready Packaging	Fast Food Clamshells, Countertop, Electronics	Inserts & Dividers, Food & Beverage, Retail Counter, Floor Displays	Fragile Goods, Warehousing E-commerce, Pizza Boxes	Inserts & Wraps, Bulky Goods, Fragile Goods

Kraft Paperboard

An eco-friendly material choice used in the production of a wide range of packaging. They are sourced from wood pulp and has a natural brown color and rough texture that gives them the rustic appearance. This is the favorite choice of brands dealing in luxury items.

Cardboard

This is the stock with one coated surface. The process called bleaching turns it white, making it like a clear canvas for adding illustrations. They are known as the best choice for printing artworks with complex details. Kraft and cardboard are used on the outside of flutes, which form the branded mailer packaging.

Printing That Turns Shipment Into A Billboard

Packaging provides a wider space for adding product details and conveying your brand message to the buyer. While ordering a product online, we’re all excited, and it goes to the next level if the product is received in custom packaging. A special note on the outside of custom printed boxes turns a normal delivery into a memorable event. At the time of ordering your custom printed postal boxes, you can consider the following printing options we are offering.

Screen Printing is the process of transferring inks from the mesh screen onto the plain sheet.
Digital Printing converts a digital file into a tangible form in the form of packaging.
Flexography is a high-speed method that works remarkably well for big projects.
Offset Printing uses metal plates to create complex artworks effectively on the desired surface.

Add-ons Promise Stronger Branding

Shipping boxes are mainly used to deliver items over long distances, and during this period they sometimes lose their original look. However, this condition only affects those boxes that are not protected with additional elements. To make sure the packaging retains its brand-new look of custom ecommerce packaging, we applied coatings and finishes. These add-ons not only serve as barriers against scratches and smudges but also provide an appealing presentation. Check out the options below:

Structural and Protective Inserts	Die-Cut Windows
	Ribbon Lifts/Inserts
	Custom Inserts
Finishing and Surface Effects	Specialty Coatings
	Embossing and Debossing
	Foil Stamping
	Spot UV / Raised UV
Unboxing and Branding Accessories	Tear Tape
	Twine, Ribbon, or Belly Bands
	Printed Inserts
	Custom Stickers and Seals
	Branded Tissue Paper

Get Instant Results!

Searching for custom mailer packaging? PremiumCustomBoxes has top-notch packaging of various types which brands get within their budget. Compromising on quality is not our policy, and we only follow procedures that promise an appealing and longer shelf life. Discount offers are available for those who place bulk orders, and the following benefits you can consider:

Free Shipping
3D Preview
Best Competitive Rates
High-end Quality
No Plates & Die Charges
24/7 Support

Packaging is the way to connect with the buyer emotionally. Don’t lose this chance with the usage of standard options, as they never communicate your message. Just by upgrading your packaging, you’ll notice a huge difference in how buyers will treat you. So, are you ready to catch the quality leads? If yes, don’t forget to fill out the quote form today!

Can I use these boxes for serving food?

Sure, we utilize food-grade material for the production of these boxes to make sure that if they are used for shipping edibles, then the items will remain contamination-free. All of our packaging is approved by the FDA & FSC.

What is the MOQ you’re offering for custom mailer packaging?

The minimum order quantity for mailer packaging is one hundred, but this will not be in your favour, as you will have to pay a higher price. The higher the order volume, the lower the price you have to pay. So make sure to place an order in bulk.

Can I use an illustration created by me for mailer packaging?

Yes, from our platform you can employ the design of your interest. Once the artwork is received, we will share the 3D preview so that you can check how the design appears on the packaging. Make sure to share the file at 300 DPI and in the file formats shared below:

JPEG
PDF
PNG
SVG

Do I have to pay after receiving the order?

No, we only accept orders after the full payment is confirmed on your side. This amount is spent on the formation of the setup required to work on your project.

Do you allow customers to add a window on the lid?

Why not? This will give the buyer an inside view of the product they want to buy. Not only that, customers who work with us can enjoy endless customization from material to printing. This supports them in leaving a powerful impression on the buyers.

Artwork Preparation Guide

Preparing artwork for various purposes, whether it's for print, digital media, or other applications, requires attention to detail and adherence to specific guidelines. Here is a general artwork preparation guide that you can follow:

Cutting Line (Red Lines):

Indicates the cut at its final size.Important artwork and text should be placed at least 0.125 inches inside of the cutting line.

Bleed Area (Blue Lines)

Indicates where the bleed line is located. Any artwork which goes to the cutting line should be extended to the bleed line to get a seamless print.

Safe Area (Green Lines):

Indicates where artwork and text should safely be placed inside. As a industry standard, all artwork should at least be placed 0.125 inches away from the cutting lines unless your design in intentional.

Perforation Lines (Red Lines)

Perforation line refers to paper that is punched with very small holes to allow the paper to be torn and folded easily.

Creasing Line (Black Lines)

Indicated where the product is to be folded.

01

Choose Your Box

Start by browsing our extensive range of box styles and designs. Whether you're in the market for something simple and classic or intricate and bespoke, we've got a multitude of options to suit your needs.

02

Customize the Design

Once you've chosen a box style, it's time to make it uniquely yours. Upload your design or collaborate with our in-house design team to craft a packaging solution that resonates with your brand's aesthetic and vision.

03

Select Materials and Finishes

Our platform allows you to pick from a variety of materials, be it eco-friendly options, premium finishes, or durable structures. Enhance the tactile experience with finishes like matte, gloss, embossing, or specialty textures.

04

Review and Approve

Before we move to production, we'll send you a digital proof or a physical sample upon request. This ensures you're 100% satisfied with the design and materials chosen. Review, make any necessary changes, and give us the green light when you're ready.

05

Production Begins

Once you've approved the design, our team gets to work. With state-of-the-art machinery and a dedicated workforce, we ensure that each box is crafted to perfection, adhering to the highest quality standards.

06

Shipment and Delivery

With our efficient logistics network, we guarantee timely deliveries. As your boxes are packed and prepared for shipment, we'll provide tracking details to keep you informed every step of the way. Sit back and wait for your premium packaging to arrive at your doorstep.

Cardboard

Corrugated

Kraft

Rigid

Anti Scratch Lamination

Aqueous Coating

Lamination

Silk Lamination Cards

Soft Touch Coating

Spot UV

Gloss Lamination

Gloss Varnish

Matt Lamination

Matt Varnish

Debossing

Embossing

Foil stamping

Window Patching

What Our Customers Say About Us

Read our customer reviews to understand product quality and service.

Sarah Johnson

4.3

★★★★★

Premium Custom Boxes has been my packaging partner since 2021. Their low rates and premium quality of custom boxes have made me a fan!

Emily Carter

4.6

★★★★★

I ordered custom cake boxes for my bakery and was amazed by the accurate details Premium Custom Boxes had made. Everything is top-notch and to the point!

Michael Brown

4.5

★★★★★

It has been 3 years since I started getting my apparel boxes from Premium Custom Boxes. Their quality has never disappointed me.

Daniel Wilson

4.5

★★★★★

Premium Custom Boxes have made my new business journey easy. I have ordered custom burger boxes multiple times from them due to their high quality.

Olivia Martinez

4.5

★★★★★

My journey with Premium Custom Boxes started in 2023. The material quality and accuracy in artwork have always been on point!

James Anderson

4.7

★★★★★

For custom boxes, my suggestion is only Premium Custom Boxes. Their durable quality and vibrant printed designs have made me confident about my product presentation.

Sophia Miller

4.4

★★★★★

I have just received my order from Premium Custom Boxes, and honestly, I was not expecting this much good quality at such low rates. Perfect!

Ethan Davis

4.5

★★★★★

Premium Custom Boxes has made it easy for me to run my coffee shop. They take care of all the pastry boxes and coffee cups with consistent quality...

Ava Thompson

4.9

★★★★★

Premium Custom Boxes has always provided me with high-end retail packaging. Their customer care service has also helped me a lot. Highly impressed with their packaging services!