Kraft Corrugated Mailer Boxes

We manufacture our kraft mailer boxes utilizing 100% post-consumer waste (PCW) unbleached softwood kraft pulp. The outer and inner linerboards specify 38-lb to 42-lb basis weights bonded to an ECT-32 or ECT-44 recycled corrugated medium. Because no chemical chlorine bleaching is applied during pulp conversion, the long lignin wood fibers remain structurally intact, delivering 15% higher tear resistance than bleached white boards.

Our standard E-Flute kraft boxes (1.6mm thickness) achieve a certified Edge Crush Test (ECT) rating of 32 lbs/inch and a Mullen burst strength of 200 lbs/sq inch under TAPPI T 810 standards. For heavier shipments exceeding 12 lbs, we convert with heavy-duty B-Flute (3.2mm thickness) or ECT-44 corrugated board, providing over 450 lbs of top-to-bottom compression resistance for palletized transit.

Yes. We operate high-density flexographic and industrial digital UV press lines capable of running multi-color CMYK directly on brown kraft. When high-contrast graphics or bright pastel tones are required, our presses lay down a flood-coat opaque white underbase before applying colored inks, preventing the natural brown fiber substrate from dulling your brand palette.

100% yes. Our unbleached kraft mailers contain zero polyethylene or plastic film laminates. We utilize water-soluble starches for corrugated fluting lamination and eco-friendly soy-based vegetable inks for printing. As a result, the entire box is fully repulpable and can be deposited directly into municipal residential paper recycling bins or industrial composting facilities.

Our direct-from-factory production minimum is 500 units per custom size and artwork version. Production lead time is 7 to 10 business days following digital 3D proof approval. For enterprise runs of 2,500 to 10,000+ units, our automated high-speed rotary die cutters reduce per-unit pricing down to $0.42 to $0.48 per box.