A corrugated mailer printed to your artwork on the outside, the inside or both, laid out on the flat blank so the print lands on the panels people actually see. Orders start from 100 units.

▧Zero Die
& Plate Costs
▣High Resolution
Offset Printing
▤High-End
Screen Print
▥Digital Printing
Solutions
♨Quick
Delivery Timing
◈100 Unit
Minimum Order
✣Custom
Design & Sizes
▦Market Competitive
Pricing

A mailer box is printed before it is a box. It is one flat sheet of corrugated, cut and creased into a blank, and the ink goes onto that sheet. Then it is folded. So the brief for a printed mailer is not a picture of a box with a design on it. It is a map of panels, and each panel has a different audience.

The doorstep panels, the opening panels, and the ones nobody sees

Folded and closed, six faces are on the outside. The top of the lid and the front are what a courier photographs and what a customer sees on the doorstep, so they carry the brand at its clearest. The two sides and the back are seen in the hand and on a shelf of parcels. They are where a return address, a size code or a repeat of the logo earns its place without competing with the lid. The base is the face the box actually stands on, scraped across every surface it is put down on, and as general practice it is left plain or given a single small mark.

Lift the lid and a second set of faces appears. The underside of the lid is the largest of them and the first thing seen at opening. The inside walls frame the product. The floor is under whatever you shipped, so anything printed there is read only after the box is empty, if at all. Then there are the panels that do a structural job and are never on show: the wings on the lid that tuck down inside the side walls, and the front flap that locks the lid shut. As general practice they are left plain, partly because print there is wasted and partly because those are the surfaces that rub against the walls every time the box is opened and closed.

Decide which of these faces matter to you before any artwork is drawn. A full wrap over every panel is a real option. Choose it knowing that some of that ink lands on faces the product covers or the structure hides.

Inside print is the other side of the sheet

Most of what you see when the lid comes up is the reverse face of the same blank: the underside of the lid, the floor, and the inside of the front and back walls. The two inside side walls are the exception. On a mailer of this construction each side wall is a panel folded back over on itself for double thickness. The surface facing the product is therefore the sheet’s outer face turned inward, and it is printed in the same pass as the outside. Printing the inside means printing the second side of the sheet, which is why it is specified as its own decision rather than assumed. It is also why an inside brief that only wants the side walls coloured is a different job from one that wants the lid. When the blank lies flat, the inside of the lid is on the back of the sheet and, once the lid folds over, it reads the other way up from the design on the lid’s outside. Artwork placed on a picture of the finished box does not carry that information; artwork placed on the dieline does. Once your size is fixed, setting the artwork onto its dieline, the right way up on every panel, is part of free design support. The mock-up you see before production is where an upside-down message inside the lid is caught.

Kraft, white, and the crease line

Corrugated is not a smooth white sheet, and the design is planned around what it does. A natural kraft base mutes printed colour, especially pale tones, so a design built on light tints is better on a white board, and White Mailer Boxes is that base. Uncoated board absorbs more ink, so colour reads softer than on a coated stock. And a heavy solid colour that runs across a crease can show the fold as a lighter line, because the ink is stretched where the board bends. As general practice, a design that lets its solid areas stop short of the creases comes out cleaner, and so does one that accepts a visible fold line as part of the look. The design to avoid is the one that pretends the creases are not there. Corners and edges take handling wear first, so the finest detail belongs in the middle of the lid rather than at its rim. 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.

The decisions this page leaves to others

Offset, digital or screen printing is chosen to suit the design and the quantity; how the run size settles that choice is set out at Custom Printed Cardboard Boxes. How the mailer closes, tuck-top, tab-lock or self-seal, is worked through at Ecommerce Mailer Boxes against how often your product comes back. If the brief is a single logo that has to sit correctly on several box sizes, Custom Product Boxes With Logo covers that. The box itself is sized to what it carries.

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.

When this is not the right box

A parcel that only has to arrive, sent to a trade customer who never looks at the box, gains nothing from print on any face, and a plain mailer does the same job for less ink. Where the question is which mailer at all, by closure, colour or material, the Custom Mailer Boxes category lays the range out and routes to each, plain options included.

Box StyleAll Custom Packaging
DimensionAll Custom Sizes & Shapes
Quantities100-unit minimum order
Paper StockKraft, corrugated, rigid board, cardstock
PrintingCMYK, Pantone, digital and offset
FinishingGloss, matte, spot UV, embossing, foiling
ShippingFree delivery options
✦ Finishing Options

Finishing & Material Options

Choose from premium coating, board, printing and finishing options for your insert boxes.

Varnish

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.

Spot UV

Spot UV

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

Soft Touch Coating

Soft Touch Coating

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.

Silk Lamination

Silk Lamination

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.

Spot Gloss UV

Spot Gloss UV

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.

Aqueous Coating

Aqueous Coating

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.

Anti-Scratch

Anti-Scratch

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.

White Kraft Paper

White Kraft Paper

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

Uncoated Unbleached Kraft

Uncoated Unbleached Kraft

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

SBS C2S Paper

SBS C2S Paper

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

SBS C1S Paper

SBS C1S Paper

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

Printing Paper

Printing Paper

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

Natural Brown Kraft Paper

Natural Brown Kraft Paper

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

Metallic Paper

Metallic Paper

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

Holographic Paper

Holographic Paper

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

Fully Recycled CCNB Paper

Fully Recycled CCNB Paper

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

Clay-Coated Kraft Back

Clay-Coated Kraft Back

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

Clay Natural Kraft

Clay Natural Kraft

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.

CCNB Paper

CCNB Paper

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

Black Kraft Paper

Black Kraft Paper

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

Window Patching

Window Patching

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

Registered Embossing

Registered Embossing

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

Hot Foil Stamping

Hot Foil Stamping

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

Combination Embossing

Combination Embossing

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

Cold Foil Stamping

Cold Foil Stamping

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

Blind Embossing

Blind Embossing

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

Blind Debossing

Blind Debossing

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.

UV Printing

UV Printing

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

Screen Printing

Screen Printing

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.

Offset Printing

Offset Printing

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

Digital Printing

Digital Printing

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.

Triple Wall Flute

Triple Wall Flute

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

Single Wall Flute

Single Wall Flute

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

Single Flute

Single Flute

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

F-Flute

F-Flute

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

E-Flute

E-Flute

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

Double Wall Flute

Double Wall Flute

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

C-Flute

C-Flute

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

B-Flute

B-Flute

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

A-Flute

A-Flute

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

Oyster White Board

Oyster White Board

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

Natural Kraft Board

Natural Kraft Board

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

Kemi White Board

Kemi White Board

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

Bleached White Board

Bleached White Board

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

UV Ink

UV Ink

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

Soy Ink

Soy Ink

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

Pantone

Pantone

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

CMYK

CMYK

A full-color printing process using cyan, magenta, yellow, and black inks to create vibrant images, gradients, and detailed packaging artwork.

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What Customers Say About Our Packaging

Real feedback from customers who trust us with their custom packaging.

Product FAQs

Frequently Asked Questions

Clear answers about ordering, artwork, production, materials and delivery.

What is the minimum order for Custom Printed Mailer Boxes?

Orders start from 100 units. Standard production takes 6 to 8 business days after approval.

Can we send the artwork as a picture of the box?

Send it if that is what you have, and it will be read as a brief rather than as print-ready art. The print is set up on the dieline for your size, panel by panel, so a rendered box is translated onto the flat blank before anything is proofed. If you already work from a dieline, ask for ours as soon as the size is confirmed and build on it directly.

Is printing the inside worth it?

It depends who opens the box. A parcel that a customer opens at home makes the underside of the lid the first thing they see. A single colour there, a line of text or a flat brand colour, does most of the work without a second full-colour pass. A box that is opened in a stockroom and emptied onto a shelf gives an inside print no audience, and the lid is where the print belongs.

Will the print scuff in the post?

Every printed parcel gets handled, and how much depends on the route. A box that goes from your packing bench to one courier to one customer is handled a handful of times; a box that is shipped in bulk to a warehouse, stored, picked and reshipped is handled many more. A coating or lamination can go over the print, subject to the specification. The route is the first thing that decides whether it is worth adding; the colour and finish chosen come next, and a dark solid has its own trade-offs. Tell us how the box travels and the finish is chosen against it.

Are Custom Printed Mailer Boxes recyclable?

An unlaminated paperboard construction may be easier to process through suitable paper-recycling streams than a heavily laminated alternative. Ink on the second face of the sheet adds nothing that the first face did not already carry. A lamination over the outside is a different matter, and it is listed on the specification if you choose one. Final recyclability depends on the full material and finishing specification and the facilities available locally.