Mailer Box
Also known as: E-commerce Box, Roll End Tuck Top, Literature Mailer
Definition
A mailer box is a style of corrugated box specifically designed for e-commerce and direct-to-consumer shipping. Unlike regular shipping boxes (RSC), mailer boxes feature a tuck-top lid that folds over and locks into place, creating a sleek, tape-free closure and premium unboxing experience.
Mailer Box Features
Design elements:
- One-piece construction
- Self-locking tabs (no tape needed)
- Clean, flush exterior
- Smooth interior surface
- Easy opening for customers
- Flat shipping and storage
Mailer Box vs. Regular Shipping Box
| Feature | Mailer Box | RSC Box |
|---|---|---|
| Closure | Tuck-top, self-locking | Tape required |
| Appearance | Premium, clean | Functional |
| Assembly | Pre-glued, fold | Fold and tape |
| Cost | Higher | Lower |
| Branding area | Excellent (interior and exterior) | Limited |
| Best for | DTC, subscription, premium | General shipping |
Common Mailer Box Sizes
| Size | Dimensions | Use Case |
|---|---|---|
| Small | 6" × 4" × 2" | Jewelry, cosmetics, small items |
| Medium | 9" × 6" × 3" | Apparel, accessories |
| Large | 12" × 9" × 4" | Multiple items, larger products |
| XL | 15" × 12" × 5" | Shoes, bulky items |
When to Use Mailer Boxes
Ideal for:
- Subscription boxes
- Direct-to-consumer brands
- Premium products
- Gift-ready items
- Products with unboxing experience
- Influencer/PR packages
Consider alternatives when:
- Shipping heavy items (RSC stronger)
- Budget is primary concern
- Industrial/B2B shipping
- Oversized products
Customization Options
Printing
- Full-color exterior printing
- Interior printing (surprise reveal)
- Simple logo stamp or sticker
- Kraft with minimal design
Materials
- White corrugated (premium look)
- Kraft (eco-friendly aesthetic)
- Colored corrugated (brand matching)
- Recycled content
Finishes
- Matte coating
- Gloss coating
- Soft-touch lamination
- Foil stamping
- Embossing/debossing
Mailer Box Costs
| Quantity | Plain White | Custom Printed |
|---|---|---|
| 50 | $1.50-3.00 | $3.00-6.00 |
| 250 | $1.00-2.00 | $2.00-4.00 |
| 1,000 | $0.60-1.50 | $1.00-2.50 |
| 5,000+ | $0.40-1.00 | $0.75-1.50 |
Custom printing minimums typically start at 100-250 boxes.
Mailer Box Suppliers
| Supplier | MOQ | Lead Time |
|---|---|---|
| Packlane | 10 | 2-3 weeks |
| Arka | 50 | 2-3 weeks |
| Fantastapack | 100 | 2-4 weeks |
| The Custom Boxes | 50 | 2-3 weeks |
| Alibaba suppliers | 500+ | 4-8 weeks |
Tips for Mailer Boxes
- Order samples first - Test fit and quality
- Right-size carefully - Too big looks cheap
- Consider inserts - Tissue, stickers enhance experience
- Design both sides - Interior is part of unboxing
- Test shipping durability - Send test packages
- Plan inventory - Custom boxes have lead times
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