Mailer Boxes, Shipping Mailers and Paper Bags

How does a mailer box differ from a postal box?

A mailer box is a folding box that ships by itself. Most have a lid hinged at the back and a front flap that tucks in. The side walls fold over, which gives the box double thickness where it takes the most knocks.

Postal box is the wider label. It includes boxes that open at the end or side, boxes that lock at the bottom, and styles built to slide into a mailbox or onto a doorstep. The bags in this range cover orders that do not need a rigid box at all.

Most shops begin with our classic tuck front mailer boxes and add other styles as the catalog grows.

How do the 17 mailer styles compare?

Use the middle column to match a style to what you sell. The last column shows how each one closes or protects.

Should I choose a box, a bag or a padded envelope?

A box holds its shape and resists crushing. Pick one for anything that can scratch, dent or break, and for orders where the unboxing matters.

A paper or film bag weighs less and lies flatter. That can move a package into a cheaper shipping tier. Bags work well for tees, hoodies and paperbacks.

Padded envelopes sit in the middle. They suit small, firm goods that need a little cushion. Our paper padded mailers for small gadgets explain how the lining works.

How do I size a mailer so it ships for less?

A close fit keeps shipping costs down. Measure the product, add a little room for tissue or an insert, then send us the inside length, width and height in inches.

Height often matters most. A box that is a quarter inch too deep can push a package into a higher price tier. A tea tin might sit in an 8 × 6 × 2 in box, while a folded sweatshirt may need 12 × 10 × 3 in. Tiny items fit our small mailing boxes for compact items.

For bags, give the flat width and length. A bag loses some usable size as it fills, so allow for the thickness of the goods.

If you sell several products, try to fit two or three into one box size. Fewer sizes mean longer runs and a lower cost per box.

Which board and wall thickness should I pick?

Most mailers use single wall E flute, about 1/16 in (1.5 mm). It folds cleanly, prints sharply and keeps the box light. B flute, about 1/8 in (3 mm), suits larger boxes or heavier goods.

For glass, ceramics and heavy gift sets, double wall BC flute at about 1/4 in (7 mm) gives much more crush resistance. Our fragile item mailers for glass and ceramics pair thicker board with inner support.

Choose white paperboard for bright color print. Choose kraft for a natural brown look, especially with one ink.

What can I print on a mailer?

The mailer is often the first thing a customer touches from your brand. Print on the outside makes the box easy to spot on a porch. Print on the inside adds a small surprise when the lid opens.

You can leave either face plain, or use one color, two colors or full color CMYK. Matte or gloss lamination, spot UV, foil stamping and embossing add a premium feel. For ideas on using both faces, see double sided printed mailers with inside art.

Every job gets a free design proof before anything is printed. Our designers will tidy your layout at no charge.

What mistakes make mailers cost more?

The costliest error is a box that is slightly too big. It needs filler, looks loose when opened and can raise shipping charges. Measure twice before you order.

Another is heavy board on light goods. E flute is plenty for most apparel and cosmetics, and it keeps package weight low.

Loose multi-item kits are a third problem. Pieces knock together in transit. A cut-out insert fixes that, and mailer boxes with fitted inserts are cut to each item.

Finally, plan the opening order. Place the thank-you card on top so it is the first thing the customer sees.

When are paper and film bags the better choice?

Not every order needs a box. Kraft paper bags with a seal strip suit apparel, books and prints. Padded versions add a cushioning layer.

Compostable bags use a film meant to break down under the right conditions. Ask us which film is used and check local disposal rules. Our kraft paper mailers for soft goods are the simplest all-paper choice.

Bags are sized by flat width and length. They print well in one or two colors, and paper styles can take full color.