Custom Printed Mailer Boxes

Die-cut, one-piece corrugated mailers for e-commerce, DTC and subscription brands. Plain kraft runs flexo on our own corrugator; full-color retail quality is litho-laminated on our offset line. Send dimensions and product weight; we engineer the dieline, board and print route, and prove it with a physical sample before you commit.

  • MADE TO CUSTOM SIZE
  • F · E · B FLUTE, ENGINEERED
  • SELF-SEAL & RETURNS-READY
  • FREE SAMPLE ≤ 5 WORKING DAYS
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Custom printed mailer box with self-seal strip and tear strip, full-color litho-laminated (example branding)

Example structure and branding shown. Dimensions, board and print are made to your order.

At a glance

Quick Specs

Product type
Die-cut, one-piece corrugated mailer box (FEFCO 0426/0427)
Flutes
E-flute (default) · B-flute · F-flute, engineered to product weight & route
Board / surface
Kraft · coated white (SBS) · grey-back white (CCNB)
Closures
Tuck-front · peel-and-seal strip · tear strip · dual-strip returns-ready
Printing
Litho-lamination full color · water-based flexo · direct UV on kraft · inside printing
Finishing
Matte / gloss / anti-scratch matte lamination · aqueous varnish
Sizes
Made to order, no fixed size chart; oversized formats via double-joined construction
Samples
Free structural + digitally printed sample within 5 working days (courier paid by buyer)
Featured structure

Self-Seal Mailer with Tear Strip

Our most-requested mailer for fulfillment lines. The closure is built into the box itself.

Inside of kraft self-seal mailer box showing peel-and-seal adhesive strip and red tear strip
  • Peel-and-seal adhesive strip. No tape, no tape gun, no water-activated paper. Peel the liner, fold, press. Packing is faster and every parcel leaves the line looking identical.
  • Returns-ready option. Add a second adhesive strip and the same box makes the round trip: open with the tear strip, reseal with strip two, send it back. One box, no extra packaging for returns.
  • Tear-strip opening. Customers open in one pull, no box cutter, no mangled flaps. The box stays photogenic for the unboxing.

Prefer a classic tuck-front mailer without strips? Also standard. We’ll recommend the right closure for your daily volume.

Kraft mailer box being opened by pulling the built-in tear strip
Board engineering

Choose Your Flute

E-flute

The mailer default. Crisp edges, a fine print surface, and solid crush protection for parcel shipping.

MAILER DEFAULT

B-flute

For heavier products or rougher shipping routes. More cushioning and more stacking strength.

MORE CUSHION

F-flute

Thin and refined, with the finest print detail. Light products and boutique unboxing experiences.

FINEST PRINT

Flute is engineered to your product’s weight and route, not fixed by a catalog. E- and B-flute board is corrugated in-house and converted fresh, never warehouse-aged stock.

Board & Surface Options

  • Coated white (SBS)

    The surface for full-color, brand-forward mailers. Best ink holdout and color reproduction.

    FSC® ON REQUEST

  • Grey-back white (CCNB)

    The economical printed option when the inner face isn’t on show.

    RECYCLED CONTENT

  • Kraft

    The natural e-commerce look, printed water-based or UV. Self-seal strips work exactly the same.

    UNBLEACHED
Print & finish

Printing & Finishing

  • Litho-laminated full color: an offset-printed sheet mounted onto corrugated: photographic quality, inside and out.
  • Water-based flexo on kraft: clean one-to-three-color logos and line work at volume pricing.
  • Direct UV printing on kraft: very high print definition straight onto kraft board. The step-up route when box graphics must be sharp; costs more than flexo.
  • Inside printing: patterns or a message on the interior face for the unboxing moment.
  • Finishes: matte or gloss lamination, anti-scratch matte for dark solid designs (so boxes don’t scuff grey in transit), or aqueous varnish where recyclability comes first.

Color is measured, not eyeballed: presses calibrated to G7 with color held in production by an X-Rite color management system, to an agreed ΔE tolerance from run to run. Pantone spot inks are available for brand-critical color.

Style library

Mailer Box Styles

One category, many closures. These are the structures we build most. All of them take the same board, print and finishing options on this page.

Self-seal mailer box with tear strip, full-color printed (example branding)

Self-Seal with Tear Strip

The fulfillment favourite shown above, with the closure built into the box.

Closure: peel-and-seal strip + tear strip; optional second strip for returns
Best for: high-volume e-commerce and subscription shipping

Kraft tuck-front corrugated mailer box with color print and QR code

Classic Tuck-Front

The standard one-piece mailer. The front flap tucks in, no tape, no glue.

Closure: friction tuck (FEFCO 0427)
Best for: presentation boxes customers keep and reuse

Locking-Tab Mailer

Die-cut side tabs snap into the front panel for a positive lock.

Closure: snap-lock tabs (FEFCO 0426)
Best for: heavier contents that push against the lid

Oversized Double-Joined

Mailer format beyond single-sheet limits, built with a joined construction.

Closure: per structure
Best for: apparel multi-packs and large flat products

High daily parcel volume
Self-seal with tear strip, no tape station, faster line, identical parcels
Returns expected
Dual-strip returns-ready, one box makes the round trip
Presentation & reuse
Classic tuck-front, no strips, opens and closes cleanly
Heavier contents
Locking-tab, positive lock against lid push
Oversized flat products
Double-joined construction keeps the mailer format

Working from a different closure or a competitor’s box? Send a reference photo. If it die-cuts, we can engineer it.

Built for Parcel Networks

Every mailer spec starts from three questions: what does the product weigh, how fragile is it, and how does it ship? From there we choose liners and flute, with ECT / burst testing available for confirmed specifications.

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Where they’re used

Applications

  • E-commerce & marketplace orders
  • Subscription boxes & kits
  • Apparel & accessories
  • Beauty & personal care
  • Electronics accessories →
  • Retail-ready boxes that ship as-is
From idea to delivery

Samples & Lead Time

Free sample: within 5 working days

A plain structural sample and a digitally printed sample (with basic lamination or varnish). Both are free; you cover only the courier. Specialty finishes like foil or UV aren’t included at this stage.

Press proof: 8 days

A production-line sample that follows the full production process, with your chosen finishes. Complex finishing adds a few days.

Production: within 15 days

Typical orders deliver within 15 days of approval; exact timing depends on quantity and finishing.

Sustainability

Corrugated mailers are widely recyclable in paper and cardboard recycling streams; recycled-content board and FSC-certified sourcing are available on request. And we right-size: a mailer matched to your product cuts dimensional weight, void fill and freight. The greenest box is the one that isn’t oversized.

FAQ

Mailer Box Questions, Answered

What sizes can you make?

Any size your product needs. Every mailer is die-cut to order, not picked from a size chart. Oversized mailers beyond a single sheet are produced with a double-joined construction, so even bulky products stay in a mailer format.

What’s the minimum order quantity?

Standard MOQ is 1,000 per size and style for litho-laminated mailers and 500 for flexo-printed mailers. Plate and die costs amortize across the run, so unit price falls sharply with volume. Smaller runs are quoted case by case. If you order inserts or shipping cartons alongside, we ship them together so the freight is shared.

Self-seal or standard tuck: which should I choose?

If you pack more than a few dozen parcels a day, the self-seal strip pays for itself in labor: no tape station, a faster line, consistent presentation. For low volumes or presentation boxes that get reused, the classic tuck-front works fine.

Can you print inside the box?

Yes. Interior printing is available on both litho-laminated and printed kraft mailers, so the unboxing moment carries your brand too.

Kraft or white: what’s the real difference?

Kraft reads natural and hides scuffs; printed white gives you the full brand canvas and the best color accuracy. The cost difference sits in the board and print route, not the structure. If you’re undecided, we’ll quote both.

How fast can I get a sample?

Free structural and digitally printed samples ship within 5 working days. You pay only the courier. A full press proof with production finishes takes 8 days.

Keep exploring

Related Products & Solutions

Get a dieline and quote in 24–48 hours

Send product dimensions, weight and target quantity. We’ll come back with an engineered dieline, a board spec and a straight price.

Helpful details: daily packing volume, target market, artwork if you have it, and whether you need a returns strip.

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