Roll End Tuck Top (RETT)
The classic mailer. Tuck-top lid with dust flaps, strongest all-round protection, works from 4 in up to 18 in long.
Ecommerce Packaging
Custom Mailer Boxes
$89.00 per pack of 100 boxes · $0.89 per box Tax added at invoicing
Free delivery to 23 markets
Total: $89.00 for 100 boxes
No payment is taken online. Add your boxes and submit the request — a packaging specialist confirms sizing, artwork and freight, then we get back to you with the final invoice and payment options once the details are confirmed.
- Free standard DHL delivery
- Free dieline, digital proof and artwork check
- 8–12 business days production, then 3–6 days transit
- 30-day replacement guarantee on print and manufacturing defects
Need a different size, quantity or finish? Build a custom spec or email sales@boxes-custom.com.
A custom mailer box is a one-piece corrugated shipper with an attached lid and self-locking side wings that ships flat, folds without tape, and carries full-colour print inside and out. It is the standard format for direct-to-consumer ecommerce because it protects the product in transit and doubles as the unboxing experience.
- No tape at pack-out. Self-locking wings cut pack time and remove tape from your consumables budget.
- Interior print included. Both liners print in the same pass, so branded interiors cost far less than a printed insert.
- Carrier-tested structure. E- and B-flute mailers are engineered against ISTA-style drop and compression profiles.
- Flat-ship storage. Blanks arrive flat and nested, cutting inbound freight and shelf space.
What are custom mailer boxes?
Mailer boxes are die-cut from a single blank, so there is no glued seam to fail under compression and no packing tape needed to close the lid. That single-piece construction is why fulfilment teams can pack a mailer in roughly a third of the time a regular slotted carton takes, and why the interior print stays visible the moment the customer lifts the flap.
The format sits between a folding carton and a heavy shipper. E-flute corrugated keeps the wall thin enough for crisp offset-quality print while still passing standard parcel-carrier drop tests, and B-flute adds crush resistance for heavier or fragile SKUs. Choosing the right flute is usually a bigger cost lever than the print itself.
Because mailers ship and store flat, warehouse footprint stays small: a thousand 10x8x4 in mailers stack into roughly the space of a single pallet layer. For subscription brands running monthly cycles, that storage efficiency matters as much as unit price.
Custom Mailer Boxes at a glance
| Box category | Ecommerce Packaging |
|---|---|
| Minimum order | 100 boxes |
| Unit price from | $0.89 per box |
| Production time | 8–12 business days after artwork approval |
| Printing | Digital CMYK, flexographic spot colour, offset litho-lamination |
| Materials | White E-flute corrugated, Kraft E-flute corrugated, B-flute corrugated, FSC-certified recycled board |
| Finishing | Matte lamination, Gloss lamination, Soft-touch coating, Spot UV, Foil stamping, Embossing, Inside-lid flood print |
| Ships to | 24 countries by DHL — free to 23, Japan quoted separately |
Custom Mailer Boxes: styles and constructions
The construction decides how the box closes, how much it protects and what it costs. These are the formats we produce most often for custom mailer boxes.
Roll End Front Tuck (REFT)
Lid tucks into the front panel instead of the top — a cleaner front-facing display face for retail-visible shipments.
Mailer with tear strip
A perforated zip strip lets the customer open the box without a knife and reduces damaged returns.
Two-piece mailer
Separate base and lid for a gift-forward reveal, usually specified for higher-ticket products.
Materials
- White E-flute corrugated
- 1.5 mm wall, bright white liner, the default for full-colour CMYK print.
- Kraft E-flute corrugated
- Unbleached brown liner, best value, ideal for one- or two-colour eco-forward branding.
- B-flute corrugated
- 3 mm wall for heavier contents, glassware, or long transit routes.
- FSC-certified recycled board
- Chain-of-custody certified stock with 70–100% post-consumer content.
Printing & finishing options
- Matte lamination
- Gloss lamination
- Soft-touch coating
- Spot UV
- Foil stamping
- Embossing
- Inside-lid flood print
Who orders custom mailer boxes
- Direct-to-consumer brands shipping via USPS, Royal Mail, Canada Post, UPS or FedEx
- Subscription box operators running repeat monthly cycles
- Apparel, beauty and supplement brands that want branded interior print
- Marketplace sellers moving from plain poly mailers to branded packaging
Popular custom mailer boxes sizes
Every order is cut to your interior dimensions — these are the sizes customers request most often, and a useful starting point if you are not sure where to begin.
| Size (L × W × D) | Typical use |
|---|---|
| 6 x 4 x 2 in | Jewellery, cosmetics samples, single supplements |
| 8 x 6 x 3 in | Skincare sets, small electronics accessories |
| 10 x 8 x 4 in | The most-ordered ecommerce mailer — apparel, candles, coffee |
| 12 x 9 x 4 in | Multi-item subscription boxes |
| 14 x 10 x 6 in | Bulk apparel, homeware, gift bundles |
How to choose custom mailer boxes
-
Measure the product, not the old box
Give us interior dimensions with 3–5 mm of clearance per side. Ordering to the outside of a competitor's box is the most common sizing error.
-
Pick flute before print
E-flute for anything under 2 kg, B-flute above that or for fragile goods. Flute choice changes cost more than the number of print colours.
-
Decide on interior print early
Interior artwork has to be supplied at the dieline stage; adding it after proofing restarts the pre-press cycle.
-
Order the size ladder together
Running two or three sizes in one production window is materially cheaper than three separate runs.
Custom Mailer Boxes pricing by market
We manufacture for brands in 24 markets. Prices below are for one pack of 100 boxes at the standard specification. Delivery is free everywhere except Japan, where air freight is quoted separately.
| Market | Currency | Per box | Pack of 100 | Excl. tax | Tax |
|---|---|---|---|---|---|
| United States | USD | $0.89 | $89.00 | — | at invoicing |
| United Kingdom | GBP | £0.84 | £84.37 | £70.31 | included |
| Canada | CAD | CA$1.22 | CA$121.93 | — | at invoicing |
| Australia | AUD | A$1.49 | A$148.81 | A$135.28 | included |
| Ireland | EUR | €1.01 | €100.71 | €81.88 | included |
| New Zealand | NZD | NZ$1.69 | NZ$168.88 | NZ$146.85 | included |
| Singapore | SGD | S$1.30 | S$129.99 | S$119.26 | included |
| Market | Currency | Per box | Pack of 100 | Excl. tax | Tax |
|---|---|---|---|---|---|
| Germany | EUR | €0.97 | €97.44 | €81.88 | included |
| France | EUR | €0.98 | €98.26 | €81.88 | included |
| Netherlands | EUR | €0.99 | €99.07 | €81.88 | included |
| Belgium | EUR | €0.99 | €99.07 | €81.88 | included |
| Austria | EUR | €0.98 | €98.26 | €81.88 | included |
| Italy | EUR | €1.00 | €99.89 | €81.88 | included |
| Spain | EUR | €0.99 | €99.07 | €81.88 | included |
| Sweden | SEK | 11.68 kr | 1,168.13 kr | 934.50 kr | included |
| Denmark | DKK | 7.62 kr | 762.06 kr | 609.65 kr | included |
| Norway | NOK | 12.02 kr | 1,201.50 kr | 961.20 kr | included |
| Finland | EUR | €1.03 | €102.76 | €81.88 | included |
| Switzerland | CHF | CHF 0.85 | CHF 84.66 | CHF 78.32 | included |
| Market | Currency | Per box | Pack of 100 | Excl. tax | Tax |
|---|---|---|---|---|---|
| Japan | JPY | ¥147 | ¥14,685 | ¥13,350 | included |
| South Korea | KRW | ₩1,322 | ₩132,165 | ₩120,150 | included |
| Hong Kong | HKD | HK$6.94 | HK$694.20 | — | n/a |
| United Arab Emirates | AED | AED 3.43 | AED 342.96 | AED 326.63 | included |
| Israel | ILS | ₪3.89 | ₪388.57 | ₪329.30 | included |
The headline price includes local VAT or GST where that market requires it. If you are VAT-registered you reclaim that, so the excl. tax column is your real cost. US and Canadian prices add sales tax at invoicing instead. Volume pricing improves at 250, 500, 1,000, 5,000 and 10,000 units — see wholesale custom boxes for the volume tiers.
Further reading
Guides from our structural, prepress and production teams that are directly relevant to specifying custom mailer boxes.
Right-sizing packaging: how box dimensions drive your shipping bill
How dimensional weight is calculated in all 24 markets we serve, and what a properly sized box actually saves.
Read the guide →Corrugated flute types explained: E, B, C, BC and EB
Wall thickness, print quality and crush resistance for every profile, and how to pick one from your failure mode.
Read the guide →Digital vs flexographic vs offset: which printing method costs less
Where the crossover points sit between the three processes, and how to cut print cost without cutting quality.
Read the guide →FAQ
Frequently Asked Questions
What is the minimum order for custom mailer boxes?
Our standard minimum is 100 mailer boxes per size and artwork. Smaller sample runs of 25–50 are possible on digital presses at a higher unit price, and pricing steps down at 250, 500, 1,000 and 5,000 units.
Do custom mailer boxes need packing tape?
No. A roll-end tuck-top mailer locks closed with its own side wings and dust flaps. Most brands add only a branded sticker or a tamper-evident tear strip for security.
What size mailer box should I order?
Measure your product's length, width and height, then add 3–5 mm of clearance per side for void fill. 10 x 8 x 4 in is the most-ordered ecommerce size; send us your product dimensions and we will confirm the closest efficient size.
Can mailer boxes be printed on the inside?
Yes. Interior and exterior liners print in the same production pass, which is why full-colour inside print costs far less on a mailer than on a two-piece rigid box.
How long does production take?
Standard production is 8–12 business days after artwork approval, plus transit. Rush production in 5–7 business days is available on most E-flute mailers.
Are your mailer boxes recyclable?
Yes. Uncoated and matte-laminated corrugated mailers are kerbside recyclable across North America, Europe and Australasia. Ask for FSC-certified recycled board and water-based inks if recyclability is a published brand commitment.