A mailer box is a type of paperboard packaging that can be easily assembled with the help of interlocking tabs without the need of any glue or adhesives.  As mailer boxes are completely collapsible, they can be shipped and stored flat to optimize shipping and storage costs.  Also known as one-piece-mailer boxes, these boxes are an ideal solution for displaying as well as safely shipping your products.  For an enhanced visual impact, these boxes can be printed full color on both the outside as well as the inside.

The folding flaps on either side of the top lid are called dust flaps. When tucked in, these flaps not only block dust from entering the box but also serve as an additional wall that adds to the vertical strength of the box.  Your account representative can help you find the most efficient solution in order to keep your total project costs low.

Generally, the top lid of a mailer boxes has two small locking tabs. These tabs act as a locking mechanism of the top lid when inserted in between the side walls. These tabs are sometimes referred to as cherry flaps and thus boxes with these flaps are referred to as cherry flap boxes. The boxes without cherry flaps are commonly to referred to as roll end tuck top boxes.

Mailer boxes that have both the cherry flaps and dust flaps are often referred to as ‘roll end tuck front’ boxes.

Mailer boxes can be produced using various types cards stocks.  Natural brown kraft card and recycled stock can be used for eco-friendly boxes.  Premium white card stocks are often utilized for high-end boxes.  Corrugated card stock is typically used for shipping boxes.  If you have any special requirements, please get in touch with one of our packaging experts to explore available options.

Yes, mailer boxes that are produced using corrugated stock can be used for shipping.  Having double walls on each side along with dust flaps, these boxes are sturdier and comparatively more damage resistant than other type of shipping boxes.  To ensure safety of the product packed inside, you can also order custom inserts to keep your product tucked safely during the shipping process.

Yes.  Options such as top opening lid and the inherent structural strength (when produced using corrugated stock) makes the mailer boxes an ideal solution for fulfilling subscription orders.  In addition to custom printing, these boxes can also be adorned with foil stamping, embossing, UV coating, and a wide range of unique lamination options.

No, there is no minimum order for mailer boxes. You can order as few boxes as you like. Ordering a few boxes is perfect if you would like a sample to check out before committing to a larger order. However, due to initial costs involved in setting up a print job, ordering bigger quantities will typically result in a lower per unit cost. Your account representative can help you find the most efficient solution in order to keep your total project costs low.

No. The emailed proofs only show how the graphics align on the box. The final print is much sharper, as long as vector or high-resolution graphics have been used in your design file. You will be contacted if your graphics appear to be at too low a resolution. If you have any concerns, please feel free to ask us a question.

You will be emailed a proof PDF file prior to the printing process. Please review the proof very carefully for accuracy. It is important that you proof read the text also check the positioning of the artwork. Artwork is printed based on the CMYK or Pantone values embedded in the design file and may vary significantly from the color shown in the proof when viewed on any particular screen. Hard copy proofs are also available at an additional cost in order to preview the exact print output before committing to a large run.