The Mailer Box
The workhorse of modern e-commerce and direct-to-consumer fulfillment. Manufactured directly on our automated flexo lines for maximum structural strength, zero-tape closure, and wholesale bulk efficiency.
Crush-Resistant Fluting
Constructed with heavy-gauge corrugated board meeting TAPPI standards for Edge Crush Test (ECT) ratings of 32 to 44 lbs/in. Withstands pallet stacking and transit shocks.
Zero Tape Required
Interlocking side ears and front closure tabs snap firmly into place, eliminating packing tape and speeding up fulfillment line assembly by up to 40%.
Full-Bleed In-House Printing
High-speed inline flexo and digital presses deliver razor-sharp barcodes, high-contrast typography, and interior brand flood colors with G7 certified calibration.
Configure Your Custom Mailer Boxes
Wholesale tiered pricing directly from the packaging floor. Receive an engineering review and guaranteed quote within 2–4 business hours.
Quote Request Received by Packaging Engineering
We are preparing your custom dieline template and wholesale volume rate breakdown. A packaging specialist will contact you at within 2–4 business hours.
Frequently Asked Factory & Manufacturing Questions
Transparent answers on minimums, production timelines, dielines, and corrugated board specifications.
What is a mailer box and how does it differ from a standard shipping carton?
A mailer box is a self-locking corrugated package featuring double-folded side walls and roll-end front tabs (RETF). Unlike standard RSC shipping cartons, a mailer box requires no packing tape or glue to seal and presents a clean, premium retail unboxing experience upon delivery.
What is the minimum quantity I can order for a custom mailer box?
Our standard factory minimum is 500 units. By ordering at this threshold, you unlock our industrial volume discounts and avoid retail broker surcharges.
Are your mailer boxes durable enough for postal transit without extra packaging?
Yes. Our mailer boxes are engineered from ECT-32 and ECT-44 certified corrugated board. They are designed to withstand postal sorting machinery and drop testing without requiring an outer master carton.
Have a technical question about burst test ratings or dieline fitment?
Consult directly with a packaging engineer via email at sales@mailerboxfactory.com or configure your specs in our Quote Configurator.