Hover to zoomCustom Mailer Boxes for Ecommerce, Gifts and Subscriptions
From £0.25 per unit Price confirmed on your written quote
Roll-end mailer boxes that fold from one flat sheet, lock shut without tape and open to a printed inside. Send your sizes and artwork, and we will return a free digital proof before anything is made.
Quick answer
What are mailer boxes?
Mailer boxes are one-piece corrugated boxes with a hinged lid that tucks into the front. They need no tape to close, post well on their own and can be printed outside and inside. Most are made in E or B flute board.
Key facts
- Folds from one flat sheet
- Locks shut without tape
- Inside print for unboxing
- Inserts can be added
- From £0.25 per unit
- Free digital proof
Mailer Boxes specifications
18 rows| Style | Roll-end tuck-front mailer with double side walls |
|---|---|
| Closure | Front tuck flap with locking ears; no tape needed to close |
| Typical board | E flute for light goods; B flute for heavier orders |
| Typical sizes | From jewellery-sized boxes up to shoebox-sized parcels |
| Inside print | Full colour inside lid, walls and base |
| Inserts | Die-cut card or corrugated inserts to hold products |
| Opening | Lid hinges at the back and lifts open in one motion |
| Delivery state | Supplied flat; folds up by hand with no glue |
| Board options | Single wall B, C or E flute; double wall BC flute; kraft or white folding board |
| Printing | Plain, one or two colour, or full colour CMYK; inside and outside print available |
|---|---|
| Finishes | Uncoated kraft, matte or gloss lamination, spot UV, foil stamping, embossing |
| Sizes | Made to your inside length, width and height in mm, cm or inches |
| Artwork files | PDF, AI, EPS or SVG preferred; high-resolution PNG or JPG accepted |
| Design help | Free layout help from our design team |
| Proof | Free digital proof before anything is printed |
| Production | 4–6 business days after proof approval |
| Delivery | Tracked, 2–3 business days; free across the UK |
| Misprints | Reported within 10 days with photos: reprinted or refunded |
Common sizes
| Inside size (L × W × H) | Good for |
|---|---|
| 150 × 100 × 50 mm | Jewellery, candles and small cosmetics |
| 200 × 150 × 60 mm | Skincare sets and accessories |
| 250 × 180 × 80 mm | Clothing, books and gift bundles |
| 300 × 220 × 100 mm | Subscription boxes and larger sets |
| 350 × 250 × 120 mm | Shoes, homeware and bulky items |
What is a mailer box?
A mailer box is a one-piece corrugated box with a lid hinged at the back. The front of the lid tucks into the base, and two small ears lock it in place.
Because it folds from a single sheet, there is no glue and no separate lid to lose. The double side walls make the box stiffer than its board thickness suggests.
Our photos show how varied they can look. One is printed all over in soft pastels, and another is kraft outside with a patterned white inside. A third is plain kraft with a printed circle logo.
Why do online shops choose mailer boxes?
They strike a balance few boxes manage. A mailer is strong enough to post on its own, yet neat enough to feel like a gift when opened.
Packing is quick too. Staff fold the box, add the product and tuck the lid, with no tape gun needed. If you sell across several box types, see the full mailer and postal box range.
- No tape needed to close
- Printable on every outside and inside panel
- Strong double walls for posting
- Opens cleanly for the customer
- Arrives flat to save storage space
Who orders mailer boxes?
Almost any business that ships small to medium items direct to customers. They are the default choice for brands that care about the moment the box is opened.
Subscription companies like them because one printed box covers every month. Gift shops like them because the lid lifts like a present.
Makers and small studios order them early on, often in plain kraft with a one colour logo. As sales grow, many move to full colour inside and out without changing the box size.
- Clothing and accessories brands
- Skincare and cosmetics sellers
- Candle and home fragrance makers
- Monthly subscription clubs
- Jewellery makers and gift shops
- Brands sending press and influencer kits
How do I size a mailer box?
Measure the product, or the product in its own retail packaging, as it will sit in the box. Then decide whether you want any tissue, fill or an insert around it.
Our measurements are always inside sizes. If you want to check how inside and outside differ, the guide on measuring a box from the inside walks through it.
- Place the product as the customer should see it on opening.
- Measure length, width and height at the widest points.
- Add space for tissue or fill on each side.
- Add the thickness of any insert.
- Send that inside size to us along with how many you need.
E flute or B flute: which board is right?
Most mailers are made in E flute. It is thin, takes print well and is strong enough for clothing, cosmetics and small gifts. B flute is thicker and better for heavier or more fragile products.
Kraft and white outer surfaces are both available. White gives brighter colour, while kraft suits a natural look.
If you are torn between the two, send us the product weight and what it is made of. We will suggest a board on the quote, and you can see how it changes the outside size.
| Board | Thickness | Good for |
|---|---|---|
| E flute kraft | About 1.5 mm | Light goods with a natural look |
| E flute white | About 1.5 mm | Bright full colour branding |
| B flute kraft | About 3 mm | Heavier items and glass |
| B flute white | About 3 mm | Heavier items with bright print |
Can the inside of a mailer be printed?
Yes, and it is one of the main reasons people choose a mailer. The inside lid is the first thing a customer sees when the box opens. A pattern, a message or a block of colour there makes a strong first impression.
In our photos, a kraft box opens to a white chevron pattern, and a teal box reveals a printed floral base. For full coverage on both faces, see our mailers printed on both sides.
How can mailer boxes keep postage costs down?
Couriers price parcels by size as well as weight. A mailer cut closely to your product avoids paying to post empty space, and it cuts down on fill too.
Shallow mailers help most. If a product can lie flat, a lower box often drops into a cheaper parcel band. Our guide to cutting postage costs on UK parcels explains how size bands work.
It is also worth checking whether two products can share one mailer. Bundled orders in a single box usually cost less to send than two separate parcels.
Do mailer boxes come with inserts?
They can. A die-cut insert holds a product in a fixed spot so it does not slide about. The teal mailer in our photos has a round cut-out for a jar, and a branded kraft box holds two items in separate bays. Our page on mailer boxes fitted with inserts shows more layouts.
Inserts are made in card or corrugated board and can be printed to match the box. Add them to the same quote so the fit is checked on one proof.
Which print and finish options are there?
Print comes as plain, one colour, two colour or full colour CMYK. You can print the outside, the inside or both. Finishes then add feel and shine where you want them.
Plan your panels in Design Your Box before you send artwork. It helps to see the lid, front and inside together.
- Uncoated kraft with a single dark ink
- Matte lamination for a soft, modern finish
- Gloss lamination for vivid colour
- Spot UV to pick out a logo or pattern
- Foil stamping and embossing for premium boxes
What mistakes should I avoid with mailers?
Mailers are forgiving, but a few slips catch people out. Here are the most frequent.
One more is forgetting the dust flaps when planning artwork. They fold inside the box, so anything printed there is hidden once the box is closed. Our designers mark these areas on the proof.
- Giving outside sizes when we work to inside sizes
- Choosing E flute for heavy glass or ceramics
- Leaving the inside plain when the outside is printed
- Placing key artwork across the folds
- Ordering one large size for every product
How do I order mailer boxes?
Mailer boxes are quoted from £0.25 per unit, and your written quote confirms the final figure. Once the proof is approved, the boxes are made in 4–6 business days. Tracked delivery takes 2–3 business days and is free to every address in the UK.
- Send your inside size, quantity and artwork or ideas.
- Choose board, print, inside print and finish.
- Check and approve the free digital proof.
- Receive your mailers flat and ready to fold.
Mailer Boxes: questions
12 answersDo mailer boxes need tape?
No. The front tuck and locking ears hold the lid shut. Some sellers add a sticker or tape strip for tamper evidence.
Can a mailer box be posted without an outer box?
Yes. Mailers are designed to travel on their own. Choose B flute for heavier or more fragile items.
What is the difference between E and B flute mailers?
E flute is about 1.5 mm thick and suits light goods. B flute is about 3 mm and suits heavier products.
Can you print inside the lid?
Yes, full colour inside print covers the lid, walls and base.
Can I add an insert to hold my product?
Yes. Die-cut card or corrugated inserts can be quoted and proofed with the box.
Do you make white mailer boxes?
Yes. White board gives brighter colours than kraft and suits full colour designs.
Do you work to inside or outside sizes?
We always work to inside sizes. That way your product fits as planned.
Can I use one mailer size for several products?
You can, with fill or an insert. A closer fit for each product usually protects better and looks neater.
Which finishes work best on mailer boxes?
Matte lamination and spot UV are popular. Foil stamping and embossing suit premium boxes.
How long do mailer boxes take?
Production runs for 4–6 business days from proof approval. Your mailers are then delivered, tracked, in 2–3 business days.
What happens if mailers arrive damaged?
Let us know within 10 days with photos of any misprint, damage or defect. We will reprint or refund those boxes.
Can I get help with my mailer artwork?
Yes. Free layout help from our designers is part of every order, shown on your free digital proof.
Not covered here? Message the trade desk on WhatsApp or email info@ordercardboardboxes.co.uk.
Design Your Box
Choose a box from the photos, place your logo on it, pick the print and send it. We turn it into a free print-ready proof.
1Choose a box
2Place your logo
Upload a logo to see it on the box
Selected: Mailer Boxes
Send us the full brief
Give us the size, the board and the print. A packaging specialist replies within one business day with a written price and a free digital proof.
- Free digital proof before anything is printed
- Production 4–6 business days after proof approval
- Free tracked delivery across the UK