The mailer box packaging is the most popular packaging solution in ecommerce market. Many brands use them to ship their e-commerce products directly into the mail. According to a report shared by Future Market Insights:
“The mailer packaging market was valued at approximately US$26.7 billion in 2023.”
The high volume recorded in 2023 shows that these boxes remain significant in the packaging industry. In this blog post, we will discuss what mailer boxes are, their types and styles, and how they help businesses create a memorable experience for their e-commerce buyers.
Let’s dig in.
What are Mailer Boxes?
Mailer boxes are specialized containers used to ship ecommerce products and enhance the unboxing experience. They are made from durable materials that provide a sturdy structure and help protect the product from damage during transit.
Now that you know what mailer boxes are, let’s discuss their popular types.
Types of Mailer Boxes
There are various types of mailer boxes available in the market; the most popular ones are as follows:
Corrugated Mailer Boxes
One of the most common and widely used types of mailer box packaging is corrugated mailer boxes. As the name suggests, they are made from durable corrugated cardboard, which provides a strong structure and excellent cushioning thanks to its fluted (wave-like) inner layer. Corrugated mailer boxes are typically available in different thickness levels, such as E-flute (1/16”) and B-flute (1/8”).
Custom Mailer Boxes
Custom mailer boxes are designed according to specific brand requirements, including shape, color, printing, and internal inserts. They help businesses create a strong brand identity and improve customer experience. Custom mailer boxes are widely used for marketing purposes, product presentation, and delivering a personalized unboxing experience to customers.
The best part is that these boxes allow size customization to meet the product’s unique requirements.
To better understand the custom and standard sizes for these boxes, read our detailed mailer box size guide.
Cardboard Mailer Boxes
Cardboard mailer boxes are lightweight yet durable packaging made from paperboard. They offer a smooth surface for printing and branding while providing reliable product protection. These boxes are commonly used for retail packaging, e-commerce shipments, and small- to medium-sized products requiring simple, cost-effective packaging solutions.
Subscription Mailer Boxes
Subscription mailer boxes are specially designed for recurring delivery services such as monthly or seasonal subscriptions. They are sturdy, visually appealing, and optimized for repeated shipping. These boxes enhance the unboxing experience, helping brands build customer loyalty while ensuring products are securely packed for consistent delivery cycles.
Kraft Mailer Boxes
Kraft mailer boxes are eco-friendly packaging solutions made from recycled kraft paper. They are known for their natural brown appearance, and they are biodegradable and recyclable. Kraft mailer boxes are popular among sustainable brands as they combine durability with an environmentally responsible design, making them suitable for organic, handmade, and eco-conscious products.
Luxury Mailer Boxes
Luxury mailer boxes are premium packaging solutions crafted from high-quality materials and finished with advanced techniques such as embossing, foil stamping, and soft-touch coating. They are used for high-end products to create a sophisticated and elegant brand image. These boxes enhance perceived product value and deliver a premium unboxing experience.
Die-Cut Mailer Boxes
Die-cut mailer boxes are packaging solutions created with a precision-cutting die to form custom shapes, openings, or design features. One popular style is the window die-cut box, which includes a cut-out section covered with a transparent film to display the product inside. They offer both functionality and strong visual appeal, making products more attractive while ensuring safe packaging during storage and shipping.
Popular Mailer Box Styles
Choosing the right style for mailer boxes matters a lot, especially when you want to ship and create a memorable experience for customers. The right mailer box style helps with fitting the product perfectly.
Here are the most popular box styles for mailer boxes:
Regular Stotted Containers
Regular Slotted Containers are the most commonly used corrugated boxes for shipping and storage. All flaps are equal in length and meet at the center when closed, forming a simple yet strong structure. They are cost-effective, easy to assemble, and suitable for a wide range of products, making them ideal for bulk packaging and transportation needs.
Roll End Tuck Front (RETF)
Roll End Tuck Front boxes feature a durable design with rolled side panels and a secure tuck-in front closure. This structure provides extra strength and a clean presentation, making it ideal for retail packaging. They are easy to assemble, reusable, and often used for e-commerce products that require both protection and an enhanced unboxing experience.
Roll End Tuck Top (RETT)
Roll End Tuck Top boxes feature reinforced rolled edges and a top tuck closure for added security. The structure offers excellent durability and product protection during shipping. These boxes are commonly used for heavier items and premium packaging, combining strength with an attractive design to enhance product presentation and ensure safe delivery.
Tab Lock Mailer Box
Tab Lock Mailer Boxes feature locking tabs that securely hold the structure in place without glue or tape. This makes them easy to assemble and highly reliable for shipping. They offer strong protection and a neat appearance, and are widely used for e-commerce packaging to ensure products remain safe during transit.
Self-Locking Mailer Box
Self-Locking Mailer Boxes feature an interlocking base and lid that automatically lock into place during assembly. This design eliminates the need for adhesives while providing strong structural integrity. They are ideal for fast packaging operations, offering durability, security, and a clean finish, making them popular for retail and e-commerce businesses seeking efficient packaging solutions.
Display Mailer Box
Display Mailer Boxes are specially designed to function as both shipping packaging and product display units. They can be easily converted into an open-front display for retail shelves. These boxes enhance product visibility, attract customers, and provide robust protection during transit, making them ideal for promotional items, cosmetics, and retail-ready packaging.
Different Types of Mailer Wraps
When it comes to mailer packaging solutions, it doesn’t stop at boxes; you can also find them in wraps for shipping delicate yet lightweight items. Here are the different types of mailer wraps:
Poly Mailers
Poly mailers are lightweight, waterproof plastic shipping bags used for non-fragile items like clothing and soft goods. They are tear-resistant, cost-effective, and help reduce shipping weight. Their self-sealing adhesive strip ensures secure closure, making them a popular choice for ecommerce brands focused on fast, efficient, and economical delivery solutions.
Kraft Mailers
Kraft mailers are eco-friendly, paper-based shipping envelopes designed for lightweight, semi-fragile products. Made from durable kraft paper, they offer a natural look and are recyclable. These kraft mailers provide moderate protection against bending and minor impacts, making them ideal for documents, apparel, stationery, and sustainable ecommerce packaging.
Bubble Mailers
Bubble mailers are padded envelopes lined with bubble wrap to protect fragile items during shipping. They absorb shock and prevent damage from impact or pressure. Commonly used for electronics, accessories, cosmetics, and small, delicate products, they combine lightweight design with robust internal cushioning to ensure safe, secure transit.
Don’t know how to mail a product using wraps? Read our detailed guide on how to mail a bubble mailer for a better understanding.
Why Ecommerce Brands Are Leaning Toward Mailer Boxes?
Ecommerce brands are increasingly choosing mailer boxes because they significantly enhance the unboxing experience, which has become a key part of online shopping. Unlike regular shipping containers, such as plain corrugated cartons, mailer boxes are designed for improved structural integrity, ease of opening, and branding opportunities.
They create a premium first impression when customers open their package, often turning delivery into a memorable moment that encourages social sharing and repeat purchases.
Benefits of Using Mailer Boxes
Mailer boxes offer a wide range of advantages for ecommerce and retail brands, making them one of the most preferred packaging solutions today. They combine durability, branding opportunities, and customer experience in one package.
- Strong Protection: Made from corrugated or sturdy cardboard, they safeguard products during shipping and handling.
- Enhanced Branding: Custom printing allows logos, colors, and designs that strengthen brand identity.
- Better Unboxing Experience: An easy-to-open design creates a premium, memorable customer experience.
- Cost-Effective: Lightweight yet durable, helping reduce shipping and packaging costs.
- Eco-Friendly Options: Many mailer boxes are recyclable and sustainable.
Overall, mailer boxes improve both product safety and brand presentation, making them ideal for modern ecommerce businesses.
Conclusion
Mailer boxes have become an essential packaging solution for modern ecommerce and retail brands due to their durability, versatility, and strong branding potential. From corrugated and kraft options to luxury and custom designs, they cater to a wide range of product needs. Their ability to enhance unboxing experiences while ensuring product safety makes them highly valuable in competitive markets. As customer expectations continue to rise, mailer boxes will remain a key driver of brand identity and overall customer satisfaction.
Frequently Asked Questions
Which is the most popular type of mailer boxes?
The most popular type of mailer box is the corrugated mailer box due to its strength, durability, and excellent product protection during shipping.
Where to get custom mailer boxes?
You can order custom mailer boxes from Custom Box Makers. They are trusted box manufacturers and have no minimum order quantity for custom boxes. Also, they deal in wholesale mailer boxes.
Are mailer boxes recyclable?
Yes, most mailer boxes are recyclable because they are made from recyclable materials, making them an eco-friendly packaging option for ecommerce businesses.
Can mailer boxes be printed on both sides?
Yes, mailer boxes can be printed on both inside and outside surfaces, enhancing branding and creating a better unboxing experiencea
