Custom mailer box styles: roll-end, tuck-top and shipping boxes
The roll-end mailer is the familiar e-commerce box: a single piece with double side walls that fold in, a lid that tucks into the front, and a clean presentation when it is opened. It suits clothing, cosmetics, accessories and subscription boxes. Tuck-top mailers are a simpler construction and often a little more economical for lighter products. Plain shipping boxes are built for protection and stacking rather than presentation, and display trays go from transport straight onto a retail shelf.
- Branded unboxing and subscriptions: roll-end mailer
- Lighter products with a cost focus: tuck-top mailer
- Heavier goods and outer packs: shipping box, usually in B-flute
- Retail-ready presentation: display tray
E-flute, F-flute or B-flute: choosing corrugated board
Flute size balances print quality, strength and thickness. F-flute is the thinnest and gives the finest print surface, so it suits small, premium mailers. E-flute is the usual choice for e-commerce: thin enough for crisp folds and good print, yet strong enough for the post. B-flute is thicker and better at absorbing knocks and carrying weight, so it is typically used for heavier products and outer shipping boxes.
White liners give brighter colours and a clean look; kraft liners give a natural appearance and tend to hide scuffs from handling.
Litho-lamination, inside printing and inserts
With litho-lamination, the design is printed by offset on a sheet of paper that is then laminated onto the corrugated board. This gives photographic detail and solid colours close to those of a printed folding carton. Printing the inside of a mailer makes the opening moment part of the brand, often with a pattern, a thank-you message or care instructions.
Tear strips let customers open the box without a knife. Inserts hold products in position so they do not move or rub during delivery, which is especially useful for glass, electronics and multi-item kits.
Printed mailer boxes: what to send for a quote
Quotes are answered within 1 business day. These details help us recommend the right flute and construction:
- Product dimensions, weight and number of items per box
- How it ships: post, courier or pallet, and whether it travels inside an outer carton
- Preferred style and flute, white or kraft liners
- Print coverage outside and inside, Pantone references
- Finishes, tear strip and insert requirements
- Quantity per size and delivery country
