
Varnish
A transparent finishing layer available in gloss, satin, or matte effects. It enhances the printed surface and adds an extra layer of visual appeal and light protection.
A mailer box with a fitted insert, laid out for a staged reveal rather than a flat, all-at-once view. Orders start from 100 units.
A press or influencer mailer gets opened differently from most parcels. It’s frequently filmed or photographed as the lid is lifted, which makes what’s seen first, and in what order, part of the actual brief.
Lay everything out on one level and a camera sees the whole thing at once, done in a single glance with nothing left to reveal. Positioning a printed card or message where it’s seen first, ahead of the product itself, gives a filmed opening a sequence rather than one flat view. Whether that’s achieved by where the card sits within the die-cut layout or a genuinely separate layer is a specification conversation worth having early, not something assumed from a standard product-shaped recess.
Where more than one item is going in, the same thinking extends across compartments rather than stopping at one. A second product revealed after the first, or a small accessory tucked beneath the main piece, keeps the sequence going instead of showing everything the moment the lid lifts.
A retail customer opens a parcel once, alone, and moves on. A press or influencer send is often filmed, photographed from several angles, and reused across more than one post, so the same few seconds of reveal get seen far more times than an ordinary delivery ever would. That repetition is exactly why the layout is worth the extra attention, in a way a one-time, private delivery never quite justifies.
The insert still has to hold the product securely once the reveal layer is lifted or moved aside. That’s its own specification question: foam, card or paperboard, chosen against what’s actually being protected and how it travels. Wherever the insert itself carries print or a message, colour matters too. Pantone references and CMYK values can be used to manage colour consistency, subject to normal variation caused by the chosen board, ink, coating and production method.
Orders start from 100 units. Design support is free. A digital 3D mock-up is free. There are no setup fees. Standard production takes 6 to 8 business days after approval. UK delivery is free.
Priorities shift once the send isn’t heading to a camera. A drop, a stacking load or a sideways jolt on a conveyor calls for matching the insert material to that specific stress, and Custom Mailer Boxes With Inserts works through exactly that. An insert alone, fitted to a mailer already in hand rather than a new box built around it, is a narrower job that Mailer Inserts handles by itself. Closures, colours and every other format live under Custom Mailer Boxes, the full range this page is one part of.
| Box Style | All Custom Packaging |
| Dimension | All Custom Sizes & Shapes |
| Quantities | 100-unit minimum order |
| Paper Stock | Kraft, corrugated, rigid board, cardstock |
| Printing | CMYK, Pantone, digital and offset |
| Finishing | Gloss, matte, spot UV, embossing, foiling |
| Shipping | Free delivery options |
Choose from premium coating, board, printing and finishing options for your insert boxes.

A transparent finishing layer available in gloss, satin, or matte effects. It enhances the printed surface and adds an extra layer of visual appeal and light protection.

A UV-cured coating applied to specific areas of the design to create gloss or matte contrast and draw attention to important details.

A smooth, velvety coating that creates a soft tactile feel and gives packaging a refined luxury look. It improves the unboxing experience and supports a high-end product presentation.

A soft, smooth lamination with a refined satin-like finish. It gives packaging a premium feel while keeping the surface elegant, subtle, and easy to handle.

A high-gloss UV coating applied only to selected design areas to create sharp contrast, highlight logos, and add a premium visual effect without coating the whole surface.

A clear, fast-drying water-based coating that adds a smooth protective layer while maintaining a clean and professional surface finish. It is a practical choice for everyday printed packaging.

A durable protective film that helps reduce visible scratches, scuffs, fingerprints, and daily handling marks. It keeps packaging looking clean, polished, and premium for longer.

A bleached kraft paperboard made from a mix of virgin and recycled pulp, offering a clean white surface for crisp and polished packaging designs.

A natural kraft paperboard without coating, made from virgin and recycled pulp. It provides a raw, organic appearance with sturdy packaging strength.

A premium bleached paperboard coated on both sides, designed for excellent print quality, die-cutting, and professional packaging results.

A high-quality bleached paperboard coated on one side. It provides a clean printable face with a premium packaging feel.

A smooth printable paper stock that supports high-resolution graphics, clean text, and rich color output for refined packaging presentation.

A natural kraft paperboard made from strong virgin and recycled pulp. It provides an organic, earthy look for sustainable and simple packaging.

A specialty paperboard with a laminated metallic surface available in gold, silver, and other premium finishes for luxury visual impact.

A specialty paperboard with a laminated holographic surface that creates a reflective, rainbow-like appearance for eye-catching product packaging.

A recycled duplex paperboard with a white printable surface. It is ideal for economical packaging that still requires clean graphics and brand presentation.

A kraft board with a smooth clay-coated white face for quality printing and a natural kraft reverse side for a strong, authentic appearance.

A kraft paperboard with a clay-coated printable top surface and a natural unbleached kraft back. It balances clean branding with a rustic natural look.

A duplex paperboard made with recycled pulp and a coated white printable surface. It delivers smooth print results for affordable carton packaging.

A black-dyed kraft board with a natural paper texture and excellent strength. It creates a bold, premium look for luxury and specialty packaging.

A packaging technique where a die-cut opening is covered with a transparent film, allowing the product inside to remain visible while staying protected.

An embossing technique where the raised design is precisely aligned with printed artwork to improve detail, texture, and overall presentation.

A finishing process in which heat and pressure transfer metallic foil to the surface, creating a premium, shiny, and luxurious effect.

A premium finishing method that combines embossing with foil stamping to create a raised design with metallic color and strong visual impact.

A decorative process that transfers foil onto selected areas of the surface using UV-curable adhesive, creating a bright metallic effect with sharp detail.

A technique that raises a design from the surface without ink or foil, giving packaging a clean, elegant, and textured appearance.

A finishing technique that presses a design into the material to create a recessed impression without using ink or foil. It adds subtle depth and a refined tactile effect.

A fast-curing printing process that uses ultraviolet light to dry ink instantly, delivering sharp detail, vibrant colors, and a premium finish.

A durable printing method that uses a mesh screen and stencil to apply ink to surfaces. It is ideal for bold colors and high-impact packaging designs.

A traditional high-quality printing process that transfers designs from plates to a rubber blanket before printing, making it ideal for large-volume production.

A modern printing method that does not require printing plates, making it cost-effective and efficient for short runs, sample production, and small-batch quantities.

Built with three corrugated layers between four linerboard sheets, providing heavy-duty strength for large or industrial packaging needs.

A standard corrugated structure with one fluted medium and two linerboards, providing dependable strength for everyday packaging.

A corrugated sheet with one flute layer between two liners, offering lightweight strength for protective packaging.

An ultra-thin flute grade designed for lightweight packaging, small retail boxes, and high-quality printed presentation.

A slim flute grade with a flatter surface, ideal for detailed printing, display packaging, and premium retail boxes.

Made with two layers of corrugated medium between linerboard sheets, offering added strength and durability for heavier products.

A versatile corrugated flute that offers balanced compression strength, cushioning, and printability for many packaging applications.

A thinner flute grade with a smooth surface, making it suitable for high-quality printing, precise die-cutting, and neat retail packaging.

A thick corrugated flute profile that provides excellent cushioning, compression strength, and stacking support for protective packaging.

A coated linerboard with an off-white surface, suitable for high-quality printing and a refined packaging appearance.

An unbleached kraft linerboard made from recycled paper pulp, offering a natural look with strong durability for eco-conscious packaging.

A coated semi-gloss linerboard with a smooth white surface, ideal for sharp printing, premium presentation, and retail-ready packaging.

A fully bleached corrugated board with a bright white surface, designed to produce clean, vibrant, and high-quality printed packaging.

A UV-cured ink that dries instantly under ultraviolet light and creates crisp, high-quality print results on a wide range of packaging materials.

A plant-based ink made with soybean oil, offering rich color output and a more sustainable printing option for carton packaging.

A standardized color-matching system used to achieve consistent, accurate brand colors across packaging, labels, and printed materials.

A full-color printing process using cyan, magenta, yellow, and black inks to create vibrant images, gradients, and detailed packaging artwork.
Real feedback from customers who trust us with their custom packaging.
Clear answers about ordering, artwork, production, materials and delivery.
Orders start from 100 units. Standard production takes 6 to 8 business days after approval. UK delivery is free.
Yes. Tell us what it needs to say and roughly where in the sequence it should sit, and that gets worked into the layout rather than treated as an afterthought once the product's own recess is already fixed.
It depends on the specification, since it's not a fixed, off-the-shelf build. Describe how you want the reveal to play out and we'll confirm what the layout can actually deliver before anything goes to production.
An unlaminated paperboard construction may be easier to process through suitable paper-recycling streams than a heavily laminated alternative. Final recyclability depends on the full material and finishing specification and the facilities available locally.