If you are looking to ship products, confidential documents, or luxury items, selecting the right mailer box size is a crucial decision. Perfect mailer boxes aren’t just about protecting the goods inside; they’re about delivering an optimal customer experience.
Did you know that, alone in the USA, product damage caused by improper packaging costs brands and businesses an average of $2 billion annually? According to the Council of Supply Chain Management, global losses from damaged goods that cannot be sold total $15 billion.
But how can one avoid this? By getting the right-sized boxes. We understand that it can be overwhelming to decide which box size is perfect for your products. But no worries. In this blog post, we will discuss the standard mailer box sizes and how to get mailer boxes for your product.
Let’s start!
What is a Mailer Box?
A mailer box is a type of packaging made from 32-ect corrugated cardboard material and comes in two different thickness levels, such as E-flute 1/16” and B-flute 1/8″. These boxes are mainly used for directly shipping products without needing an additional shipping box.
They are lightweight compared to other shipping boxes and come with built-in interlocking flaps for secure, tape-free assembly. Ideal for e-commerce and personal use, mailer boxes provide a customizable surface for branding and create a memorable unboxing experience for items like clothing, electronics, and gifts.
Mailer boxes also come in different structural styles depending on the product and shipping requirements. You can explore the different types of mailer boxes
Now that we know what mailer boxes are, let’s discuss standard sizes.
Mailer Box Sizes & Dimensions
Mailer box sizes depend on what type of product you want to store in them. This will help you determine whether you need a small, medium, or large mailer box.
Small Mailer Boxes Sizes
Think of a small cube; that’s what small mailer boxes look like. A small mailer box size ranges from 3” x 3” x 1.01” (L x W x H).
Here are the industry-standard box sizes for small mailers:
- 3” x 3” x 1.01”
- 3” x 3” x 2”
- 6″ × 6″ × 2″
- 7″ × 5″ × 2″
- 8″ × 6″ × 2″
These sizes are ideal for lightweight items, such as jewelry, accessories, candles, and other similar products.
Medium Mailer Boxes Sizes
A medium mailer box is almost similar to a shoe box. Medium mailer boxes are a perfect and safe choice, as they are versatile and can accommodate a wide range of products, including bags, clothes, shoes, and small appliances.
Here are the industry-standard sizes for the medium mailer boxes:
- 9″ × 6″ × 3″
- 10″ × 7″ × 4″
- 12″ × 9″× 3″
- 14″× 10″ × 4″
- 16″ × 12″ × 4″
These boxes are a perfect choice for retailers who want to utilize their space and improve shipping efficiency.
Large Mailer Boxes Sizes
Large mailer boxes can store oversized items or multiple items for retail businesses. Their sturdy composition and thoughtfully designed structure help resist damage and harm during the shipping process.
Here are the industry-standard sizes for large mailer boxes:
- 20″ × 15″ × 6″
- 24″ × 18″ × 10″
- 30″ × 24″ × 12″
- 36″ × 24″ × 12″
These large-sized mailer boxes are ideal for packing bulky clothing accessories, bedding sets, pillows, sports equipment, and more.
If you are looking for the standard dimensions of the other boxes, you can visit our blog on standard box sizes.
If your product does not fit these common mailer sizes, use our box size calculator to estimate a practical custom box size based on your product dimensions and packing requirements.
How To Measure Your Custom Mailer Boxes?
To determine the correct size for your custom mailer boxes, it is essential to know how to measure both your product and the box.
To measure your product, lay it flat on a surface and measure its length, height, and width. Once you have these measurements, you have to add 0.723 inches to these dimensions for your box. To understand better, you can read our detailed guide on how to measure your product dimensions for a perfect box.
However, if you don’t have your product lying around, you can work through the existing mailer box. All you have to do is unfold the mailer box on a flat surface, and then, with the help of a ruler or measuring tape, measure the length, height, and width of your box. These will be more accurate sizes for your next order. You can also visit our blog on how to measure your box dimensions for a better understanding.
Determine Whether You Need Void Fill or Not
Void fill is the material used to fill the space inside packaging, providing cushioning to protect products. This could be box inserts, bubble wrap, tissue paper, kraft paper, or packing peanuts.
Whether you need void fill depends on what you’re shipping. Fragile items, such as glassware, ceramics, or jars, require extra space, so your mailer box needs to be larger. Non-fragile products like chips, sweets, or coffee beans can be packed snugly without void fill since there’s no real risk of damage.
Always measure internal Dimensions
Once you know your product size and whether void fill is needed, focus on internal box measurements. Suppliers list internal dimensions because that’s what ensures your product fits properly inside the box.
External dimensions only matter if you’re calculating shipping costs or figuring out pallet space. For product fit, use internal dimensions when selecting your mailer boxes.
Final Thoughts
Picking the right size mailer box is important for both your brand and your customers. A proper fit keeps products safe, reduces wasted space, and avoids extra packaging. It also makes unboxing simple and enjoyable, leaving a positive impression of your brand. When your boxes are measured right, they do more than protect the product. They also create a smooth experience that adds value for the customer and helps your brand stand out in a competitive market.
Frequently Asked Questions
What is a large mailer box?
A large mailer box is a packaging solution designed to ship bigger items safely. It is typically made of sturdy cardboard and provides sufficient space to hold products securely without damage.
Is there any benefit in having large mailer boxes?
Yes, large mailer boxes protect your products during shipping, reduce the risk of returns due to damage, and give your customers a professional unboxing experience.
Which material is best for mailer boxes?
Corrugated cardboard is the best choice for mailer boxes. It is strong, lightweight, and can be customized with printing or branding to make your packaging look professional.
Why do I need to invest in mailer boxes?
Investing in mailer boxes ensures your products arrive safely, boosts brand image, and creates a positive experience for your customers, which can lead to repeat orders.
