What Is a Mailer Box? Types of Mailers Explained
W
hamburger menu icon
search iconlogo
search icon
Shop by Industry
Boxes & Packaging
Labels & Stickers

What is a Mailer box? What are the types of mailers?

date read icon January 27, 2025
Mailer box packaging

Are you looking for the core purpose of using a mailer box? Well, these are sturdy packages used for shipping items. Mailers are often made from cardboard, cardstock and corrugated cardboard, but with variation, other materials can also be utilized. In the world of packaging competition, all-high custom mailer boxes are an impeccable solution for businesses. These boxes have an aesthetic appeal, making them a popular choice for businesses. From extending the product presentation to transportation experience these are utilized for many facets. When choosing custom mailer boxes you can explore their manufacturing process as this determines the cost you will be bearing.

What Are Custom Mailer Boxes, and How Are They Made?



Custom mailer boxes are typically made from corrugated cardboard, a material popular for its strength, recyclability and lightweight properties. 

Want your packaging to really pop? Glamour mailers are where it's at. Think shimmering gold, a classic black, or maybe a bold red or deep purple; these are not just your average mailers; these are like mini works of art! They are brilliant for businesses that want to add a touch of class, whether you're shipping clothes, jewelry, or those extra-special gifts.

Do you know the best part about them? These are quite super easy to use. No more fighting with rounds of tape. They've got these handy self-sealing flaps, so packing is quick and painless. Plus, if you're sending something a bit delicate, many of these mailers come with bubble lining inside to keep everything safe and sound during its journey.

Picture this: a sleek, efficient version of the classic cardboard box. That’s your mailer box! Simple in design but brilliant in function, these boxes typically feature flaps that fold in to form the structure and either a tab or adhesive to keep it sealed during its journey.

Why is Mailer Box the First Choice?


1. Protection First

Mailer boxes are the go-to for shipping everything from small gadgets to fragile items like glassware or ceramics. With a snug, reinforced fit, your products stay safe and sound no matter how bumpy the ride.

2. First Impressions Matter

Who doesn't love a good unboxing experience? Mailer boxes give you the perfect canvas to show off your brand. Add your logo, some bold artwork, or a personal message to leave a lasting impression and turn every delivery into a mini-event!

3. Efficiency + Convenience

These boxes are built for speed transit. These are easy to assemble and easy to ship, and some even come with extra perks like handle cutouts or tear-away panels for super simple openings.

What Makes a Mailer Box Great?


1. Reinforced for Safety

Look for sturdy boxes with added layers or corrugated material. The more reinforced, the better your products will survive any rough handling on their way to you or your customer. 

2. Extra Features are a Win

Think handle cutouts for easier carrying for your mailer box packaging, tear-away panels for smooth opening, or even built-in padding for delicate items. Moreover, you can come up with designing mailer box ideas adding a touch of features. These mailer boxes are more convenient. It's up to you whether you require a mailer box vs a shipping box, as it's handy and compact.

3. Branding Goldmine

Your mailer box isn't just for shipping. It is your brand's handy billboard! Customize it to make your brand pop, and make your packaging as memorable as the product inside. 

Mailer Boxes for Every Business:


1. E-commerce Dynamic Boxes

If you’re running an online store, mailer boxes are a must. They offer a sleek, professional look and are perfect for getting your products to customers quickly and safely. A small mailer box dimensions are as follows:

Mailer Box Dimensions 

6" × 6" × 2"

7" × 5" × 2"

8" × 6" × 2"

9" × 6" × 3"

10" × 7" × 4"


2. Subscription Box

For subscription services, mailer boxes are likely your best bet if you want to make a mark on customers. Consistent, stylish, and able to deliver that "wow" factor with every box, your subscribers will look forward to receiving their next one!

3. Gifts Made Simple

Are you planning to send a gift to someone special? Make it extra special, as gift packaging has to be of exceptional quality with a thoughtfully designed mailer box. It's the kind of packaging that makes the gift-giving experience even more exciting.
The manufacturing process involves:

Corrugated Cardboard Formation:

 A wavy layer called "fluting" is sandwiched between two flat cardboard layers, glued together for enhanced strength.

Cutting and Trimming:

 With a plethora of options, there can be cutting in specific sizes and shapes for cardboard boxes. From picking the appropriate trimming machines to adding intricate details. Moreover, adding things like handles or perforations is the best way to go.

Assembly:
 Boxes are shipped flat or pre-folded using bending machines, ready to be assembled into sturdy packaging.
This process ensures that mailer boxes are not only functional but also eco-friendly and customizable to suit various business needs.

Types of Custom Mailer Boxes

There are several materials you can count on when designing your custom mailer boxes. Below are some types of mailers popular and adopted by several industries.

Mailer Box vs. shipping box



Generally, mailers and shipping boxes are interchangeably used, but there's a difference between them. Mailer boxes are usually compact for smaller, lighter items, while shipping boxes are for heavier and larger items.

Mailer boxes are often more cost-effective, while shipping boxes are more durable. Using mailer boxes for quicker fulfillment needs is easier compared to their counterparts.

Corrugated Mailer Boxes



Ideal for shipping fragile or heavy-duty items, corrugated mailer boxes offer exceptional shock absorption. They are perfect for electronics, crockery, and even compact furniture, ensuring your products remain intact during transit.

Flat Mailers & Chipboard Mailers



When it comes to flat mailers, chipboard mailers are durable and lightweight mailers ideal for shipping important documents. It encapsulates photos, certificates legal documents so that these reach your mailing address safely. These mailers prevent your items from being folded or bent and keep their integrity intact. Flat mailers have a variety of sizes and are available in brown, kraft, and black colors. In addition, there are several styles, self-sealing, tab closure and gusseted mailers for bulky shipments.

Magnetic Closure Mailer Boxes



Magnetic closure mailer boxes are something more than convenience as they add up protective gear. These are box magnets in the lid that close and open the box. These can be paired with a variety of products, including jewelry, cosmetics and electronics, for added functionality. These are among the types of mailers which are stunning and spell-binding.

Padded Mailer Box



Have you got something very fragile to ship? Padded mailers are the way to go, as they are soft and come with a cushioned interior. These soak up any knocks and bumps along the way, keeping your products snug and safe. They are perfect for electronics and jewelry books and suitable for anything you require. The padded mailers come in a variety of colors and sizes, From the classic brown kraft to white options. These are lightweight, so you won't have to worry about any sky-high shipping costs.

Eco-Friendly Mailers

These days, more and more people are looking for eco-conscious choices, and eco-friendly mailers fit the bill perfectly. Made from materials that can be recycled or that will biodegrade naturally, they let you do your bit for the environment while still making sure your products arrive in perfect condition.

These mailers come in various styles, too, including reinforced ones for extra strength and gusseted ones for bulkier items. They all have those easy self-sealing flaps, which is a bonus. By choosing these mailers, you're not just looking after your customers' packages; you are showing them that your business cares about being sustainable, which is a big plus in today's global landscape.

Kraft Mailer Boxes



Kraft mailers are often known as eco mailers and are considered environment-friendly packaging choices. These mailers are typically made from recyclable materials and are tailor-made to your brand's specifications. Kraft mailers are a packaging option for various products that are lightweight and non-fragile.

Cardboard Mailer Boxes



You can add a touch of sophistication and durability to your mailer boxes excelling to create a memorable unboxing experience. These boxes are tailored with vibrant graphics, unique patterns and brand logos as it helps to captivate customers at first glance. Cardboard box mailers are best suited to add a touch of exclusivity to your products.

Rigid Mailer Boxes



When it comes to shipping high-end products you definitely require premium packaging. Rigid mailer boxes are your go-to choice; they are durable yet protective and appealing. These also exude a luxurious feel, making them a perfect choice for high-value items. 

Type of Mailer Wraps

To stand out and make your mailer packaging a reliable one, you definitely want personalized mailer wraps. These are also a good option for shipping your ecommerce and retail products. These wraps are integral to meeting guidelines and shipping services but also go easy on your budget. Many manufacturers and retailers know that making your mailer boxes secure is something important before you ship your products.

Here are some of the options for wraps that bring convenience to shipping your products.

Bubble Wraps



Polythene bubble wraps are the perfect option for safely packing and mailing compact and small products. The delicate nature of small items requires you to wrap them around as the bubble wraps add a cushioning effect, ensuring safe transit. These polythene bubble wraps add an extra layer of protection to fragile products.

Foam Wraps



wraps are also a good alternative to bubble wrap. These wraps are made of spongy foam providing an excellent shock-absorbing effect during transit. Like bubble wraps, foam ones also perform best if used to provide additional cushioning in the mailer boxes.

Benefits of Custom Mailer Boxes

There are several custom mailer boxes 

1. Ultimate Durability During Transit

Custom mailer boxes are designed to withstand external pressures, protecting your products from damage during shipping. Their robust construction ensures that even delicate items reach customers in perfect condition.

2. Lightweight and Convenient

When it comes to the standout features of custom mailer boxes these are lightweight. Not only reducing shipping costs but making them easy to handle and assemble, enhancing efficiency in logistics.

3. Cost-Efficiency

These mailer boxes are recyclable and biodegradable materials, these boxes are budget-friendly without compromising quality. The recyclability and affordability make them a viable option for all-size businesses. 

3. Fully Customizable

Customization is an intrinsic way from where mailer boxes shine by deciding on size and shape. You can add exclusivity for design and color; these boxes can be tailored to match your brand's personality. This versatility showcases professionalism and enhances your brand's recognition. Customizability is an intrinsic element that properly showcases the brand's voice and enthralling appeal.

Why Choose the Right Mailer Box Style?

Selecting the appropriate style for your mailer boxes is crucial for both functionality and aesthetics. The right style ensures that products fit snugly, reducing movement during transit and aiding in efficient stacking for bulk shipping.

Conclusion

When we discuss mailer boxes, these stand out more than packaging, designed strategically to enhance brand identity. You can ensure product safety and optimize costs as with the right type of design, you can cater to an unforgettable customer experience. Reap a more durable and eco-friendly packaging that promotes brand elements as well.

Ready to transform your packaging strategy? Explore the endless possibilities of custom mailer boxes and give your business the edge it deserves. The packaging aficionados are just one step away; reach out to Print247 the premier packaging brand in the States!

Author: Bill ‘Hogg’ Ryan
AUTHOR

Bill ‘Hogg’ Ryan

Bill is a Houston-based packaging writer with 6 years in the industry. His hands-on career began with printing machines; he has built profound expertise in custom packaging solutions across multiple sectors, including cosmetics, food, and retail. A recognized industry contributor in the State. Bill now shares insights through writing, focusing on packaging trends and innovations. In his leisure time, he can be seen riding his favorite Stallion, ‘Tex,’ or jamming to country music.