A Complete Guide to Custom Mailer Box for Your Product Packaging

Most brands use a custom mailer box to create a unique unboxing experience for their customers. E-commerce and retail packaging businesses print logos and use their brand colors to create a lasting impression. 

Using durable and eco-friendly materials, these boxes protect products in storage and in transit. In this guide, we explain why custom-printed mailer boxes are the best option for product packaging. 

What Is a Custom Mailer Box? 

Most custom mailer boxes are crafted from corrugated cardboard, which offers superior strength and protection compared to other paper-based packaging materials. These boxes typically feature interlocking tabs that secure the structure without the use of glue or tape. 

Unlike stock or blank shipping cartons, which are plain brown and sealed with tape, you can customize a custom mailer box. You can add logos, messages, and patterns to help build your brand. Customizing polymailers, which are plastic envelopes, is challenging. 

When you customize the boxes to fit the products perfectly, you save on space and shipping costs. 

Types of Custom Mailer Boxes

Shipping boxes, also known as custom mailer boxes, come in various styles. The importance of custom packaging cannot be underrated, with its industry expected to grow to 95.87 (USD Billion) by 2034. Depending on the products you want to package, you can choose from any of the types.  

Tuck-Top Mailer Boxes

These boxes have a lid that folds over the top and tucks in front of the box to close it. The edges are precisely cut with side flaps that snap into position, giving the custom mailer boxes strength without requiring any adhesive or tape.

Most businesses will use it as a mailing gift box, as it is easy to open and close. 

Adhesive Tear-Strip Mailer Boxes

Adhesive tear-strip mailer boxes have a pre-applied strip of strong glue that seals the box. They have an inbuilt tear strip that opens cleanly once pulled. Customers can determine if someone has tampered with the packaging by checking if the tear strip is broken. 

Many brands use adhesive tear-strip mailer boxes for added protection, particularly when packaging electronics or luxury cosmetics. 

Mailer Boxes without Wings

Mailer boxes without wings have a simple lid with no side flaps or wings. The lid folds over the top and tucks into the box. They have a clean appearance and are easy to open. 

Brands use them primarily for hand-delivered packages, as they are slightly less secure due to the absence of side wings.  

Material Options of Customized Mailer Boxes

You have a wider selection of material choices for customizable mailer boxes. Each type of material offers a different level of strength and cost effectiveness. 

Corrugated Cardboard

Corrugated cardboard consists of three layers, with the middle layer having a wave-like shape. Often referred to as the fluted layer, it adds additional durability and padding to the box. Although strong and lightweight, corrugated cardboard is available in a range of thicknesses.  

Corrugated cardboard is a reliable, sustainable, and strong enough material for shipping. 

White Cardboard

White cardboard is made from pressed paper pulp and a bright white coating. Its primary purpose is presentation, more than heavy protection. 

White cardboard has a clean surface, making it ideal for printing quality logos and designs, helping your brand look more professional. 

Recycled Cardboard

Previously used paper or cardboard is broken down, cleaned, and pressed into new sheets. Recycled cardboard has a slightly rougher texture than regular cardboard.  Depending on the product's needs, recycled cardboard can be single-layered or corrugated. 

Companies aiming to highlight their commitment to sustainability often choose custom printed mailer boxes made from recycled cardboard.

Kraft Paper

With brands moving towards sustainability, Kraft paper is an ideal option. It’s a strong brown paper that gives a natural and rustic appearance.

Kraft paper is an affordable and environmentally friendly option, perfect for packaging handmade goods or natural products.

Chipboard

Chipboard is made by pressing together small pieces of recycled paper or cardboard. It is lightweight, smooth, thin, flat, and easy to fold. Chipboard is not as strong as corrugated cardboard, and it's not ideal for heavy items. 

Most brands use chipboard for light-duty packaging or those that want a premium look without using heavy materials. 

Key Benefits for Your Business

1. Product protection & structural integrity

Mailer boxes are strong, and the flaps prevent the products from falling out. They are also durable due to the use of long-lasting corrugated cardboard that makes up their structure. 

Corrugated cardboard is puncture-proof and crush-resistant. 

2. Cost-efficiency & lightweight design

Because the custom mailer boxes are lightweight, they are cheaper to ship. Widely used materials for making custom mailer boxes, such as corrugated cardboard, are affordable and budget-friendly. 

The boxes don’t need filler materials, which increase shipping costs. They are also easier to stack, eliminating wasted space. 

3. Branding & marketing impact

When you print your logo and message on the custom mailer box, it becomes a marketing tool for your brand. Instead of plain packaging, its scalable graphics become a powerful branding opportunity. 

The unboxing experience becomes an exciting one for clients who may share it on their social media accounts. Most people tend to throw away plain brown boxes. Custom mailer boxes will give you repeated impressions as they are reusable, allowing your brand to stay visible for longer. 

4. Enhanced customer experience

A well-designed box not only holds products, but also makes the receivers feel special. Opening the custom mailer box feels more like a gift than receiving a product, helping to build a strong connection with your brand. 

5. Sustainability credentials

Natural brown kraft is the primary material in corrugated cardboard. It is fully recyclable and environmentally conscious, making it an excellent option for businesses seeking sustainable packaging alternatives.

Design Consideration

Consider choosing a design that creates a lasting unboxing experience. 

Know your audience & SKU range

Knowing what features your clients like best is the first step in designing the customizable mailer boxes. Which shapes, colors, and sizes do they like? 

Creating a custom profile helps you understand their various needs. Some prefer working with sustainable brands that give them reusable packaging options.   

Structural design & protection

When creating a custom mailer box, the structure is essential. Getting the right size ensures the product fits well and is protected. The design should also allow easy folding and closing. 

Using strong materials such as corrugated cardboard protects the products during shipping. Adding features such as inserts and cushioning helps hold and protect the products. 

Artwork, branding & messaging

A well-thought-out mailer box with proper placement of logos and messages creates a unique and memorable impression. 

Create beautiful brand artwork for seasonal or campaign graphics. 

Unboxing experience

With reusable features, companies are selecting mailer box suppliers that help deliver a memorable unboxing experience for their customers. Adding features such as product cards or stickers shows clients that you care. 

A clean layout with beautiful interior graphics makes the product look neat and enhances the overall enjoyment.

Material and print finishes

Choosing the right material and print finish for custom mailer boxes is crucial for both looks and quality. White offset paper gives a clean appearance, while kraft paper lends a friendly one.

Digital printing is ideal for small orders with detailed designs and lots of colors. Flexo printing is perfect for larger orders with simple designs. Consider adding coatings and varnishes for added protection.

Operational & Cost-Aspects 

It's essential to consider related expenses when selecting the appropriate material and dimensions.

Sizing optimization

Large boxes occupy a significant amount of space, resulting in higher costs for both weight and volume. However, using the right-sized boxes reduces wasted space and shipping costs. 

Smaller boxes are also easier to pack, store, and handle. 

Production methods

The production method you choose for custom mailer boxes can significantly impact both the quality and cost. Digital printing is a cost-effective solution for short runs or small quantity orders, as it avoids the use of printing plates and shortens setup time

Picking the right method helps manage your budget and production needs. 

Total cost of ownership

Apart from the cost of each custom mailer box, it is essential to consider all the associated costs. Consider which material or printing method will fit your budget. 

You should also consider the order minimums, as most manufacturers have specific requirements. Custom packaging pays off when you want to boost your brand or improve customer experience. 

Sustainability-driven sourcing

Most brands today are opting for eco-friendly materials, such as recycled cardboard or safer inks, for their sustainable packaging.

Avoiding non-recyclable finishes, such as shiny foils or plastic coatings, also contributes to sustainability efforts. 

Conclusion

Choosing the ideal customer mailer boxes requires considering the materials, design, and the specific type that best fits your brand. 

At Brothersbox, we offer custom mailer boxes at wholesale prices, allowing our clients to operate within their budgets. Contact us for customer mailer boxes that can meet your packaging solutions.