Hover to zoomCustom Roll End Tuck Top Boxes with Inside Print
From £0.25 per unit Price confirmed on your written quote
Roll end tuck top boxes are the classic one-piece mailer: the side walls roll over into double thickness ends, and the lid tucks in at the front. We make them to your inside size and send a free digital proof first.
Quick answer
What are roll end tuck top boxes?
A roll end tuck top box is a one-piece corrugated mailer whose end panels fold over on themselves to make double thickness walls. The lid is hinged at the back and tucks into the front, often held by two small locking ears. It ships flat and folds up without glue or tape.
Key facts
- Double thickness rolled ends
- Tuck-in lid with locking ears
- Prints inside and outside
- No glue or tape to assemble
- From £0.25 per unit
- Free digital proof
Roll End Tuck Top Boxes specifications
18 rows| Style | One-piece mailer, ends roll over into double walls |
|---|---|
| Closure | Hinged lid with front tuck and side locking ears |
| Typical board | E flute for slim mailers; B flute for heavier contents |
| Typical sizes | From jewellery mailers to shoebox-sized parcels |
| Inside print | Common; lid, walls and base can all be printed |
| Inserts | Corrugated or card inserts slot into the base |
| Thumb notch | A cut-out on the front makes the lid easy to lift |
| Assembly | Folds from flat by hand with no glue or tape |
| 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 |
|---|---|
| 160 × 120 × 50 mm | Jewellery, cosmetics and small gifts |
| 220 × 160 × 70 mm | Skincare sets and subscription items |
| 300 × 220 × 90 mm | Folded clothing and books |
| 350 × 250 × 120 mm | Larger gift sets and homeware |
What is a roll end tuck top box?
It is the box most people picture when they think of a mailer. A single sheet of corrugated card folds into a tray with a hinged lid.
The name comes from the ends. Each end wall folds over on itself and locks into the base, giving a wall twice the usual thickness. The lid then tucks in at the front.
Our photos show several examples. One has a bright red printed inside, another a gold pattern on black, and a pink one carries a short message inside the lid.
Why are the ends rolled?
Rolling the end panels does two useful jobs. It adds strength where parcels are most often knocked, and it hides the raw edges of the board.
The rolled ends also form small pockets that hold the lid's dust flaps. That is why the box stays square and closes neatly without glue.
In practice this means the box keeps its shape when parcels are stacked in a sorting depot. Corners stay crisp, and the lid lines up when the customer opens it.
Who orders roll end tuck top boxes?
This style suits anyone who posts products straight to customers and wants the box to feel like part of the purchase.
It also suits small runs of special items, such as launch kits or press packs, where the box itself needs to impress. A plain kraft version works for everyday orders too.
- Subscription services sending monthly boxes
- Beauty brands posting skincare and make-up sets
- Clothing and accessory shops sending folded items
- Gift companies packing hampers and curated sets
- Businesses sending welcome packs to new staff or clients
How does it compare with other mailer styles?
Roll end tuck top is not the only mailer we make. The table shows where it sits next to the alternatives, so you can choose with confidence.
If your products are light and you post a lot, an ear lock mailer can be quicker to fold. When the box needs to look and feel solid, the rolled ends are worth it.
| Style | Ends | Closure | Feel |
|---|---|---|---|
| Roll end tuck top | Double thickness, rolled | Tuck lid with ears | Sturdy, premium unboxing |
| Ear lock mailer | Single walls | Ears lock into slots | Light and quick to fold |
| Tuck top mailer | Single walls | Front tuck flap | Simple, economical |
| End opening mailer | Opens at one end | End tuck | Slim items such as books |
How do I size a roll end tuck top box?
Measure everything that goes inside, including any insert, tissue or card. Then send us the internal length, width and depth.
The rolled ends take up a little room inside, so it is important to work from inside sizes, not outside. We allow for the folds when we draw the box.
Keep the depth close to what you need. A deep mailer with a shallow product leaves space for things to move. The guide to measuring inside box sizes explains the difference.
Which board works best for this style?
E flute, about 1.5 mm, is the most popular choice. It folds crisply, keeps the box slim and prints very well inside and out.
B flute, about 3 mm, gives more cushioning for heavier or more fragile contents. The rolled ends become even stiffer in B flute.
Board comes with a white or kraft outer face, and the choice changes the mood of the box more than any finish. White suits full colour print, and kraft suits a simple one or two colour design.
If you are torn between the two, think about weight. Light goods such as cosmetics, jewellery and clothing sit happily in E flute, while glass, ceramics and heavier sets suit B flute. Our corrugated flute guide in millimetres compares them side by side.
How should I print a roll end tuck top box?
Inside print is where this style shines. When the lid lifts, the whole inside is on show, so a colour or pattern there makes a big difference.
Many brands keep the outside simple, with a logo on the lid, and save the bold design for inside. That also keeps the parcel discreet in transit.
Finishes such as matte lamination, spot UV or foil work on the lid. Keep them away from fold lines, where coatings can crack.
A short line printed inside the lid, such as a thank you or care note, costs nothing extra once inside print is chosen. Customers often photograph it.
How do I fold and pack this box?
The box arrives flat. Folding takes a few seconds once you have done it twice.
After a few dozen boxes, most packers can fold one in under ten seconds. Keep a folded sample on the bench as a guide for new staff.
- Lay the sheet printed side down and fold up the side walls.
- Fold each end panel up, then roll its inner flap over and down into the base.
- Push the locking tabs into the slots in the base to hold the ends.
- Place your product, insert and any card inside.
- Fold the lid over and tuck the front flap in, pushing the ears into their pockets.
What mistakes should I avoid?
Most problems come from sizing and artwork placement. A careful look at the proof catches nearly all of them.
Hold the real product against the proof drawing and imagine it folded. It is the quickest way to catch a problem before printing.
- Sending outside sizes when we need inside sizes
- Choosing a depth far greater than the product
- Putting key text across the fold where the end rolls over
- Forgetting that the lid flap tucks in and hides part of the front
- Using B flute for small, light items that suit E flute
How do I order roll end tuck top boxes?
Send your inside sizes, board choice and artwork by email or WhatsApp. Our designers will place everything on the flat layout and send it to you as a proof.
If you are new to mailers, tell us what you are sending and roughly how heavy it is. We will suggest the flute and a sensible depth.
Once you approve the proof, production takes 4–6 business days. Tracked delivery then follows, arriving within 2–3 business days.
You can also explore shapes and print options in Design Your Box before you send your details.
What do roll end tuck top boxes cost?
Prices for this mailer start from £0.25 per unit, with the final figure set out on a written quote. Inside print, B flute and finishes all affect the total.
Orders ship free to every UK address. Should any mailers be misprinted or damaged, send photos within 10 days for a reprint or refund.
Roll End Tuck Top Boxes: questions
12 answersWhy is it called roll end tuck top?
The end walls roll over on themselves to make double thickness ends, and the lid tucks in at the top front.
Do these boxes need tape?
No. They fold and lock together without glue or tape. Some people add a sticker or tape for extra security in the post.
Can you print the inside of the box?
Yes. The lid, walls and base can all be printed inside, which is one of the main reasons people choose this style.
Which flute should I choose?
E flute suits most mailers and gives a slim, neat finish. B flute adds cushioning for heavier or fragile contents.
Is this style strong enough for posting?
Yes. The rolled ends add strength at the corners, and it is designed to go through the post as the outer box.
Can I add an insert?
Yes. Card or corrugated inserts can sit in the base to hold products in place.
What is the thumb notch for?
It is a small cut-out on the front edge that makes the lid easy to lift open.
Should I give inside or outside sizes?
Inside sizes. We allow for the folded ends and board thickness when we draw the box.
Can I have a kraft outside and white inside?
Tell us the look you want and our team will advise on the board faces available for your order.
How long does an order take?
Production takes 4–6 business days once the proof is approved, then tracked delivery takes 2–3 business days.
Do the boxes arrive folded?
No, they arrive flat to save space. Each one folds up by hand in a few seconds.
Can I use this box for subscriptions?
Yes. It is one of the most popular styles for monthly subscription and gift boxes.
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: Roll End Tuck Top 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