Custom Mailer Boxes with Inserts for Sets and Kits

What is a mailer box with an insert?

It is a standard folding mailer with a second piece of board inside, cut to hold your products. The insert sits on the base, and each item drops into its own slot or recess.

Our photos show the range of shapes. A kraft box has a single rectangular cut-out in a raised platform. A green-lined box has an L-shaped cavity. A bright green mailer holds a row of round products, and a kraft box carries a die-cut card cradle for two bottles and a round jar.

If you only need loose inserts for boxes you already have, see our separate corrugated inserts made to fit.

Why add an insert to a mailer?

Without one, products move as the parcel is lifted, turned and set down. Bottles knock together, labels scuff and lids can work loose.

An insert locks each item in place, so the load cannot shift. It also means you need less paper fill, which speeds up packing and gives a cleaner look when the box opens. For sets, it shows the customer at a glance that everything is there.

There is a branding gain too. A layout with every product sitting upright in its own space looks deliberate and finished, which is what you want from a gift box.

Which insert style suits my products?

The right choice depends on the shape and weight of what you send. Round items suit cavities; flat or boxed items suit a platform. Bottles often need a cradle that holds both the neck and the base.

For mixed sets, inserts can combine styles. A platform with one large cut-out for a boxed item can sit beside two round cavities for jars. Tell us everything that goes in and we will sketch a layout on the proof.

How do I measure products for an insert?

Measure every item at its widest point, including caps, pumps and labels. A bottle with a pump top is taller and wider at the top than the bottle alone.

Send us the sizes of each product and how you want them arranged, side by side or in rows. We then work out the box inside size around the insert, rather than the other way round. A photo of the products laid out is very helpful. Our guide on measuring boxes and products accurately covers the basics.

If you have samples, tell us whether sizes vary between batches. A cut-out that is a snug fit for one bottle may be tight for the next.

Can the insert be printed?

Yes. Inserts can be left plain or printed to match the box. A kraft insert in a kraft box looks natural, while a printed insert in the same colour as the inside walls gives a fully finished look.

We print plain, one colour, two colour or full colour CMYK, on the box inside and out. Finishes include uncoated kraft, matte or gloss lamination, spot UV, foil and embossing. A line of text on the insert itself, such as product names under each cut-out, is a nice touch for sets.

Printed inserts cost more than plain ones, so many brands print only the box. A plain kraft or white insert still looks tidy, especially when the products themselves carry the colour.

Which board should the box use?

The box carries the full weight of the set, so pick the board by the total packed weight. Light sets of tins or vials are fine in E flute at about 1.5 mm.

Glass bottles and heavier kits are better in B flute at about 3 mm. The thicker wall also gives the insert more to push against. If your set is very heavy, ask us whether a double wall shipping box as an outer carton makes sense.

Common mistakes with inserts

Most problems come from measurements. Measuring a bottle without its cap, or a jar without its label, leaves a cut-out too tight to use.

Another mistake is leaving no lid space above the tallest item. If the lid presses on a pump top, it can depress it in transit. Finally, ordering inserts separately from the box often leads to a poor fit. Quoting both together avoids that.

It also helps to think about the customer taking items out. A cut-out that grips too tightly is hard to lift from; a thumb notch at one side makes it easy.

Can you make foam inserts?

One of our photos shows a grey foam insert, which some brands use for electronics. Our standard inserts are corrugated and folding board, which are light and arrive flat with the box.

If you think you need foam, tell us what the product is. We will suggest a board insert that does the same job, or confirm on the quote what we can supply.

Board inserts can be surprisingly protective. A raised platform lifts the product away from the base, so knocks to the bottom of the parcel do not reach it directly.

Ordering mailers with inserts

Box and insert are quoted together, from £0.25 per unit for the box, with the full price set out in writing. Start with our box and insert quote form, or email product photos to info@ordercardboardboxes.co.uk.

Our designers plan the insert layout for free. You get a free digital proof of both pieces, then production takes 4 to 6 business days. The finished boxes reach you by tracked delivery in 2 to 3 business days, with no delivery charge anywhere in the UK.