Custom Fragile Item Mailers Made to Fit Your Products

What is a fragile item mailer?

It is a mailer box built for things that break. The box style is familiar, but the board, sizing and inner packing are chosen with the product's weak points in mind.

Our photos show the idea. A kraft mailer has FRAGILE printed across the front, with glasses beside it. A navy box is marked with a printed label panel and warning panel. Others are full colour mailers in kraft and white board, closed and ready for the post.

For mugs in particular, our dedicated mug shipping boxes may be a closer fit.

Which board should I choose for breakables?

Board choice is the biggest decision for fragile goods. Thicker flutes have more air inside the board, which takes up the force of a knock. Read about the trade-offs in our guide to single wall versus double wall boxes.

Remember that heavier board also means a heavier parcel. If postage is tight, a fitted insert in a B flute box can protect as well as a loose item in double wall.

How much space should I leave around the item?

Enough for your cushioning, and no more. Wrap the item first, then measure it wrapped, and use those numbers as the inside size.

If you use an insert instead of wrap, measure the bare product and tell us. We size the insert to the product and the box to the insert. Either way, the item should not move when the closed box is shaken gently.

Give your sizes in mm, cm or inches, and include the item's weight. Weight helps us choose between single and double wall.

Odd shapes need a little thought. A jug with a handle should be measured across the handle, not just the body, and the handle wrapped on its own first.

Wrap, fill or insert: which protects best?

Each has its place. Paper wrap is quick and flexible, which suits mixed orders. Paper fill around the item stops it shifting but needs care to pack evenly.

Inserts hold the item in a fixed position, which suits repeat products like a set of glasses or a candle jar. They pack faster and look neater, but each insert is made for one product shape. Many shops combine methods: a fitted insert for the main item, plus a sheet of paper over the top. Our crinkle paper shred for void fill is a common pairing for gift boxes.

Should the box say fragile?

It helps. Printed marks tell handlers to take care and tell your customer to open the box gently. A single word on two sides is often enough.

We print plain, one colour, two colour or full colour CMYK, inside and out. Fragile marks look clean in one colour, like the white text on kraft in our photos. Inside, a short note on how to unwrap glass safely is useful. Finishes include uncoated kraft, matte or gloss lamination, spot UV, foil stamping and embossing, though most fragile mailers stay uncoated or matte.

Is a box inside a box worth it?

For very delicate or valuable pieces, yes. Pack the wrapped item in a small inner box, then set that inside a larger mailer with fill all round. That puts two walls and a cushion between the item and any knock.

It takes more time and board, so most sellers keep it for their most fragile lines, such as thin glass, large ceramics or one-off art pieces. We can make both the inner and outer boxes to size on the same order, so they fit each other properly.

For everyday goods like mugs and jar candles, a single well-fitted mailer with good wrap is normally enough.

Who uses fragile item mailers?

Our customers for this style are mostly makers and small shops. Potters, glass artists, candle makers and homeware sellers post breakable goods every day.

Gift companies sending glasses for weddings or birthdays use them too, as do drinks brands posting bottles with branded glasses. For anything taller than it is wide, ask us about a tuck top build, which takes height more easily.

Ordering fragile item mailers

Fragile mailers start from £0.25 per unit; thicker boards and inserts add to that, and your written quote shows it all. Use our fragile mailer quote request with product sizes and weight, or WhatsApp us photos.

We send a free digital proof, then make the boxes in 4 to 6 business days after you approve it. Delivery is tracked, takes 2 to 3 business days, and is free to any UK address.