
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.
Custom cookie mailer boxes built to survive courier handling and transit, not just a shop counter, printed to your brand on kraft or corrugated stock. Orders start from 100 units, with free design support and a free digital 3D mock-up before production.
A box that works fine handed across a counter can fail completely in a courier’s van. Cookies get stacked under other parcels, tipped on their side, and jolted at every sorting point along the way. A mailer box is designed around that journey instead.
A retail cookie box only has to survive being carried to a till and home again. A mailer box has to survive a courier network: sorting, stacking, and a van ride that can last several days. Corrugated stock resists crushing under stacked weight better than a single-layer board, which is why it is the common choice for anything travelling any real distance. Kraft can still suit a shorter journey or a smaller, lighter shipment, where keeping the parcel light matters more than maximum crush resistance. A divider or insert reduces movement inside the box, so cookies do not slide and chip against each other or the box wall during that journey. Where the cookies themselves are buttery or iced, a coated printing face resists grease better on the surface the food actually touches, the same trade-off that applies to any food-contact board. Your logo and branding print in CMYK or to your Pantone references, subject to normal variation caused by the chosen board, ink, coating and production method.
Standard production takes 6 to 8 business days after approval. That figure covers making the box itself, so it sits before shipping starts rather than including it. A buyer working to a delivery deadline needs to plan for both stages, since dispatch and transit time are confirmed separately once production is booked.
Board and coating can be selected to suit direct or indirect food contact depending on the specification. Food-contact material suitability is confirmed for the specific material before production, and allergen and nutritional labelling stays your business’s responsibility.
This carton is built for transit protection and branding, not for guaranteeing an outcome. No packaging can promise every cookie arrives intact regardless of how it is handled in transit, and any claim that says otherwise is overselling what board and an insert can actually do. What a well-specified mailer can do is meaningfully reduce the movement that causes breakage.
Design support is free. A digital 3D mock-up is free before bulk production, so you can see how the insert and closure sit together before committing to a run. UK delivery is free. There are no setup fees.
An unlaminated corrugated or kraft construction may be easier to process through suitable paper-recycling streams than a heavily laminated alternative. A plastic window or heavy lamination will change that, so recyclability depends on the full make-up of the box you choose. We can talk you through the considerations for your specification.
Getting your box right starts with telling us roughly how far the box typically travels and whether the cookies are individually wrapped, so we can size the insert and choose the right stock. Prefer general shelf packaging over a shipping format? Biscuit Packaging Boxes covers that instead. Comparing mailer formats across other products? Custom Mailer Boxes puts them side by side. To compare every food box style, see Custom Food Boxes.
| 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.
A mailer has to handle a courier network rather than a short counter-to-bag handover. It needs to resist crushing under stacked weight in transit, and a divider keeps cookies from sliding and chipping against each other along the way.
No packaging can guarantee that outcome regardless of handling, but a well-specified mailer with the right insert meaningfully reduces the movement that causes breakage. Tell us how the cookies are packed inside and we can suggest the right divider.
No. Standard production takes 6 to 8 business days after approval. That is the time it takes to make your box, and dispatch and transit then run separately once it leaves us. UK delivery is free.
Yes, this format is built for exactly that kind of order. Tell us roughly how far the box typically travels and how many cookies per shipment, and we can suggest a stock and insert that suits it.
Orders start from 100 units. Standard production takes 6 to 8 business days after approval. UK delivery is free.