Mailer Boxes

What Is a Mailer Box?

Cut from a single sheet, a mailer folds into a tray with a lid hinged at the back and a flap that slots in at the front. Ear locks at the sides hold it shut, so it closes without tape and opens like a gift. Customers see the inside first, which is why mailers are the favourite box for subscription services, clothing brands and online shops that care about the unboxing.

Why Do Online Shops Prefer Mailers?

They look finished. A well-fitted mailer needs no outer carton, holds its shape on a doorstep and gives a clean surface for a logo. It also packs quickly once a packer has made up a few.

• Opens neatly without a knife
• Closes without tape, or with one strip for security
• Strong on all sides thanks to rolled double walls
• Prints well inside and out

E Flute or B Flute?

E flute is the slim grade: crisp folds, a flat face and clean detail in the artwork. It is the right choice for most mailers up to a shoebox or so. Move up to B flute when the contents are dense or the mailer is big enough that its lid could sag. The board guide with every flute grade compares both.

Printing Inside the Lid

Lift the lid and the underside is what the buyer meets first, which makes it prime space for a message or pattern. A short thank-you message, a pattern or a web address inside, with a simple logo outside, makes a strong impression without the cost of full colour on every surface.

How Do You Size a Mailer Box?

Measure the product or the set of products laid out as they will sit in the box. Mailers work best when the contents fill the footprint and the height is just enough to close the lid without bulging.

1. Lay the items out as they will be packed.
2. Measure the length and width of that layout.
3. Measure the tallest point for the height.
4. Add a few millimetres each way, more for tissue or inserts.
5. Send the inside size with the quantity.

Do Mailers Need Inserts?

If you send one product that fills the box, no. If you send several items, or anything that could slide, a card insert holds each piece in place and turns the box into a presentation pack. Inserts are quoted alongside the mailer and fitted to its inside size.

What Do Mailer Boxes Cost?

Plain mailers start from £0.20 a box in compact sizes. Print, board and size move the price: 1 colour outside costs less than full colour inside and out. Ask for two options on one quote if you are weighing up the difference.

Making Up Mailers at Speed

A mailer folds in four moves: the base, the two side walls with their ear flaps, and the lid. New packers get quick within an hour. For busy weeks, make up a stack in advance; made-up mailers nest poorly, so keep them on a shelf rather than in a pile.