Yes. We provide food-grade mailer boxes that conform to the regulations. These mailer boxes help in maintaining the freshness and sterility of the food due to their tight closing system.
The construction of our mailer boxes starts from 2 ply, one E flutes layer of corrugated material. It is the most simple combination for a mailer box. Only screen printing could be done there. However, it is recommended to go at least for a 3 ply mailer box with 220 GSM cardboard on top of the E flutes. If inner printing is needed, then we will make printing and paste an additional 220 GSM cardboard making it 4ply.
Yes. Double-sided printing on mailer boxes enhances their looks and provides additional branding space.
Yes, you can pick out certain inserts which help organize your goods in the boxes. It makes the opening process more interesting due to the neat packaging.
Certainly. Custom mailer boxes can be made using rigid materials that create an impression of premium quality products due to their elegant appearance. In addition, we also provide add-on options.
The retailers make use of customized mailer boxes to send their goods to the end-users. Shipping boxes on the other hand ship goods in bulk. The manufacturers and other industrial companies utilize them to send their goods to the stockpiles and the retail places.
A brown shipping box says nothing about the brand that sent it. It arrives, gets opened and gets tossed without a second thought. A custom mailer changes that interaction completely. The doorstep becomes a brand touchpoint. The opening becomes a moment.
Custom Mailer Boxes from our production use E-flute and B-flute corrugated in roll-end front tuck construction. E-flute at 1.5mm handles lightweight products like apparel, cosmetics and subscription items. B-flute at 3mm takes heavier products needing stronger crush resistance through courier networks. Inside print on the lid interior transforms the unboxing from functional to branded. White, kraft and colored corrugated stock all available depending on the brand aesthetic.
Premium does not mean over-designed. It means every detail was considered and none were accidental. Premium Custom Mailer Boxes from our production use soft-touch matte lamination, spot UV logo accents and foil stamping on corrugated exteriors. These finishing techniques on a mailer format signal investment the recipient notices before the tear strip is pulled.
Inside print in brand color creates the reveal moment. Tissue paper coordination, sticker seal closure and printed insert cards layer the unboxing experience. The mailer costs more per unit than a plain box. The brand impression it creates costs nothing additional per recipient it reaches.
No single mailer format fits every product or every fulfillment workflow. diverse mailer boxes from our production cover every structural type. Tuck top mailers fold closed with interlocking flaps. Tab lock mailers use side tabs for secure closure without adhesive. Roll-end front tuck formats wrap around the product with a clean front panel. Here is how mailer format maps to product and workflow:
E-flute and B-flute are not interchangeable. Using B-flute on a lightweight product over-packages and inflates dimensional weight shipping cost. Using E-flute on a heavy product under-protects and risks transit damage. Mailer Boxes from our production match flute type to product weight precisely.
E-flute handles items under 500 grams. B-flute handles items between 500 grams and two kilograms. Double-wall BC flute takes products above two kilograms where single-wall fails. ECT edge crush ratings get specified per the carrier handling class the mailer enters. The box survives the courier because it was rated for that courier specifically.
Packing room speed depends on how fast the box closes. Tape guns slow the process. Glue requires drying time. Staples damage product. convenient mailer boxes from our production use a self-seal adhesive strip on the closure flap. Peel the liner. Press shut.
Done. Tear strip perforation on the opening edge gives the buyer a clean tool-free opening. Dual peel strip mailers add a second adhesive strip beneath the first for return-ready resealing. The buyer peels, refolds and drops the same mailer back in the post. No tape needed. No new box needed. Convenience runs both directions.
Carriers charge by dimensional weight, not actual weight, on lightweight products. An oversized mailer inflates the DIM weight calculation and the shipping invoice alongside it. Mailer packaging from our production gets dimensioned to the actual product footprint with minimum clearance.
Tight sizing reduces DIM weight, reduces void fill, reduces material cost and reduces the carbon footprint of every shipment simultaneously. Furthermore, flat-pack mailer delivery to fulfillment warehouses maximizes pallet density during storage. The mailer earns its place in the supply chain by saving money at every stage from warehouse to doorstep.
A subscription box with the subscriber name on the exterior turns a delivery into a personal event. Personalized Mailer Boxes from our production use digital variable data printing for individual names, loyalty tier messaging and account-specific offers on the mailer exterior or interior lid.
Short runs from one hundred units make personalization viable for VIP customer programs and high-value subscription tiers. The mailer arrives addressed to the person. Not to the current resident. Not an occupant. To them specifically. That distinction drives retention metrics subscription brands measure monthly.
Black mailers communicate premium before the brand logo even registers. The dark surface reads as intentional, considered and high-end. Black Mailer Boxes from our production use dyed-through black corrugated where the color penetrates the board fiber. Scuffs barely show on the dark surface.
Gold or silver foil stamping on black corrugated creates contrast that photographs exceptionally well for unboxing content. White ink print on black stock delivers reversed-out brand identity no lighter substrate replicates. Edge color stays black at score lines because the dye runs through the entire board thickness.
White corrugated gives full CMYK print the clean substrate it needs for accurate color reproduction. White Mailer Boxes from our production use white liner corrugated on E-flute and B-flute.
Brand colors print without the warm shift kraft substrate creates. Photographic product imagery reproduces at the resolution offset litho-label application delivers. The mailer surface works as hard as the design team intended because the substrate is not fighting the artwork.
A mailer box that needs a second box around it defeats the purpose of being a mailer. Corrugated Mailer Boxes from our production rate directly for courier network transit per ISTA testing standards. ECT compression is under sorting belt stacking.
Board weight handles drop impacts at carrier specified heights. The mailer is the shipping container. No over-box. No secondary packaging. No wasted material. The product goes in. The mailer closes. The label goes on. The courier picks it up. That simplicity is the operational advantage mailers exist to deliver.
Kraft mailers communicate sustainability without a single printed word saying so. The natural brown fiber reads as eco-conscious, authentic and intentional. Kraft Mailer Boxes from our production use virgin kraft corrugated entering standard OCC recycling streams cleanly.
No plastic lamination. No foil barriers. Soy-based ink handles the brand print. Water-based aqueous coating protects the surface through courier handling. Single-color logo on kraft creates the artisan register eco-positioned DTC brands depend on. The material does the messaging before the ink even starts.
Flat print media bends under stacking pressure if the mailer does not resist it. A catalog arriving with a creased cover wasted every dollar the brand spent producing it.
Literature mailer boxes from our production use rigid E-flute corrugated with full-overlap flap construction doubling panel thickness at the top and bottom. Spine width accommodates page count precisely. Internal card stiffeners prevent flex across the mailer span. The literature arrives flat, crisp and increased because the mailer was specified for that specific fragility profile.
Holiday mailers turn every December delivery into a gift presentation before the product inside is even revealed. Holiday mailer boxes from our production carry seasonal artwork, festive color palettes and holiday messaging on the exterior and interior surfaces.
Digital print handles limited-edition seasonal designs without plate investment. The mailer swaps into the fulfillment workflow for the holiday window and swaps out when the season ends. Standard brand mailers resume in January without any structural change to the packing process.
Brand color on a mailer creates instant recognition at the doorstep before the recipient reads the label. Colored Mailer Boxes from our production use Pantone-matched dyed corrugated or full-surface printed color on white liner stock. Dyed-through color stays consistent at score lines and edges. Printed color offers a wider Pantone range at lower minimum order. Here is how colored mailer stock gets specified:
Small products in oversized mailers look lost and rattle during transit. Small Mailer Boxes from our production die-cut to compact dimensions matching jewelry, cosmetic samples, phone accessories and subscription sample kits precisely.
E-flute at minimum wall thickness keeps the mailer proportional to tiny products without over-packaging. Internal die-cut card inserts hold small items centered and visible. Dimensional weight stays minimal because the box dimensions match the product. Compact mailers also stack more units per pallet during fulfillment warehouse storage.
Fulfillment operations packing hundreds of mailers per hour need a closure method that takes one motion. Tuck top flaps interlock without tape, adhesive or tools. Tuck Top Mailer Boxes from our production use auto-lock bottom with tuck top closure.
The packer drops the product in, folds the top flap and tucks. Done. Sub-three-second pack time per unit. The tuck holds secure through courier transit without popping open under sorting belt vibration. Reopening at the customer end pulls the tuck free cleanly. No tearing. No box destruction. The mailer survives for return or reuse.
A December delivery in a plain brown box sits in a pile of other plain brown boxes. A Christmas mailer stands out from the doorstep. Christmas Mailer Boxes from our production carry holiday-specific artwork including snowflake patterns, festive typography, seasonal color palettes and gift-tag messaging on the exterior.
Inside print adds holiday greeting copy visible at the unboxing moment. Digital print runs seasonal artwork at short-run quantities without plate cost. The brand runs Christmas mailers for six weeks and returns to standard packaging without any structural changeover at the fulfillment station.
Not every mailer needs corrugated construction. Flat premium products like stationery sets, photo prints, certificates and luxury invitations ship in heavy SBS cardboard mailers instead. Cardboard Mailer Boxes from our production use 400 GSM SBS with scored fold construction.
The smooth unfluted surface takes offset litho print at photographic quality no corrugated surface matches. Matte or gloss lamination protects the print through postal handling. The mailer feels more like a presentation folder than a shipping box. That material quality signals premium before the contents are visible.
Some brands prefer blank mailers branded at the packing station with adhesive labels, rubber stamps or sticker seals. Blank Mailer Boxes from our production ship in unprinted kraft, white or colored corrugated stock ready for in-house branding application.
Stock sizes in common e-commerce dimensions ship without custom die-cut lead time. The blank format keeps unit cost at minimum. The brand applies identity at the fulfillment point using whatever method their workflow already uses. Labels for some orders. Stamps for others. Stickers for seasonal promotions. Flexibility without custom print commitment.
Cookies generate moisture from residual baking heat trapped inside a sealed box. That moisture condenses on the inner surface and softens the cookies during transit. Cookie Mailer Boxes from our production use food-grade PE-lined corrugated with ventilation perforations releasing moisture before condensation forms.
Grease barrier coating prevents butter oil from soaking through the base. The cookies arrive crispy, not soggy. The box arrives clean, not stained. FDA food-contact compliant inks handle the brand print. The mailer ships baked goods the way the baker intended them to arrive.
E-flute and B-flute corrugated, SBS cardboard, self-seal adhesive, tear strip perforation, inside print, digital personalization and food-grade lining all run from one facility. No corrugated from one vendor, printing from another and adhesive application from a third creating quality gaps between the structure and the finish.
The Packaging Tree, A home bakery shipping fifty cookie mailers weekly gets the same food-grade barrier testing as a subscription brand running twenty thousand mailers monthly.
Tear strip pull force gets tested on the actual corrugated stock. Self-seal adhesive bond gets verified under the temperature range the mailer will encounter between warehouse and doorstep. Mailers are the most personal packaging format in e-commerce. The one carrying your brand should feel like that mattered.
Visa, mastercard, paypal etc
6-8 business days
2D & 3D mock ups
Premium custom boxes
We are offering premium quality services for your personalized Custom Box Packaging. Besides, we provide Offset and Digital Printing.
The Packaging Tree is a one stop solution for the short-run Custom Packaging, Custom Printed Boxes, Wholesale Custom Boxes needs and supplies. At affordable prices. Request a free quote.
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