From earthy 100% recycled kraft to bleached white boards and soft-touch tactile varnishes, your choice of substrate and coating dictates how customers perceive your brand the moment they touch the package.
The foundation of any custom mailer box is the outer linerboard. At Mailer Box Factory, we convert with two primary paperboard grades:
Crafted from unbleached virgin and post-consumer recycled pulp, natural kraft delivers an authentic, eco-friendly aesthetic. It is especially suited for bold black typography, earthy single-color flexo designs, and brands emphasizing circular sustainability.
Features an ultra-bright white clay-coated face sheet. It provides the neutral backdrop required for true-to-life Pantone color reproduction, rich photography, pastels, and vibrant full-coverage CMYK printing without color shifting into brown paper fibers.
Coatings protect printed graphics from scuffing against postal sorting equipment while elevating the customer's tactile unboxing experience:
| Coating Type | Visual Appearance | Tactile Feel | Ideal Applications |
|---|---|---|---|
| Matte Soft-Touch | Velvety, glare-free, satin finish | Ultra-smooth, luxurious soft hand-feel | Apparel Sleeve Mailer → |
| Gloss Aqueous (AQ) | Vibrant, high-contrast reflective shine | Smooth, polished paper surface | Printed Mailer Boxes → |
| Spot UV Varnish | High-gloss raised clear varnish over matte background | Dimensional tactile contrast between smooth and raised elements | Mailer Boxes with Inserts → |
| Raw Uncoated Kraft | Warm earthy fiber texture, organic brown hues | Natural tactile wood pulp grain | Standard Mailer Box → |
Our advanced flexographic and digital converting lines can print on both sides of the corrugated sheet in a single inline pass. This allows you to combine a clean, understated exterior with a high-impact branded interior reveal:
Explore our dedicated Printed Mailer Boxes page for full-bleed double-sided dieline layouts.
Request a direct-from-factory sample kit containing printed kraft swatches, white coated samples, soft-touch coatings, and spot UV treatments.