Custom Mailer Boxes

Little Rock Packaging’s Custom Mailer Boxes deliver durable, eco-friendly packaging designed for secure shipping and outstanding brand presentation. Fully customizable in size, print, and structure, these mailers enhance unboxing experience while protecting diverse product types.

Box StyleCustomized, Tuck Flap Box, Pillow Box, Gable Style , Sleeve Style Box , Mailer Style Collapsible Mag Closure etc.
DimensionDimension or the size of the box is usually measured with the help of Length x Width X Height Formula ( Height = Top to Bottom of the box), Width (Left to right of the box) and Length front to back of the box.
SizeAll Custom Size and standard sizes are Available.
Quantities100 to 500,000 boxes can be ordered in one month.
Paper Stock10pt to 24pt (60lb to 400lb) Eco-Friendly Kraft, E-flute Corrugated, Bux Board, Cardstock, Uncoated Super White Cardboard and Rigid Stock.
Printing TypeOffset printing Method, Screen Printing, Plain, CMYK Colors, PMS (Pantone Matching System), Spot Colors.
Finishing Or Add onsSoft Touch Lamination ,Gloss Lamination, Matte Lamination, Gloss AQ, Gloss UV, Matte UV, Spot UV, Embossing Debossing and Foiling.
Additional OptionsCreasing , Die Cutting, Gluing, Perforation, Blind Embossing, Window Patching, (Gold, silver, Copper, Red, Blue Foil Stamping)
Design ProofingBox Template (free), Flat View, 3D Mock-up, Physical Sampling (On request Paid)
Turnaround TimeStandard Turnaround Time:After getting the artwork approved, it takes 9 to 11 business days for producing the boxes and further 24 to 48 Hours for the shipment to be delivered at your doorstep. Custom add on orders can take 2 to 4 days extra.
Expedite Turnaround TimeOnce the job is sent for production after the approval of artwork the production will take at least 4 to 6 Biz days for printing and further 24 to 48 hours for delivery at your doorstep. Urgent deadlines can be achieved.
Shipping servicesWe use DHL, FedEx USPS and UPS to Ship boxes. Sea shipping is also an option that can be considered on specific requests.

Introduction

Little Rock Packaging’s Custom Mailer Boxes are expertly engineered shipping solutions that combine structure, style, and sustainability. Crafted from strong corrugated cardboard, these self-locking boxes provide robust protection for products while being lightweight enough to reduce shipping costs. Perfect for e-commerce businesses, subscription services, and retail brands, these mailer boxes offer a premium unboxing experience that drives customer satisfaction and brand loyalty. Designed to be fully customizable, they allow brands to create packaging that aligns perfectly with their identity and product specifications.

Why Are Custom Mailer Boxes the Best Choice for Your Packaging Needs?

Our custom mailer boxes stand out by offering the optimal balance of protection, ease of use, and customization. Unlike typical bulk shipping boxes, mailer boxes are designed for direct consumer shipments, featuring self-locking closures that eliminate the need for additional tape, thereby speeding up packing and reducing material waste. The sturdy construction safeguards fragile items such as skincare, snacks, electronics, and apparel from damage during transit. Additionally, the fully customizable exterior offers unlimited branding opportunities—from logos to color schemes and messaging—enhancing brand recall and customer engagement.

Customizable Features for a Perfect Fit

Little Rock Packaging offers vast personalization options for custom mailer boxes, allowing brands to specify dimensions, structural styles, and printed graphics. Choose from a range of sizes to precisely fit your product and reduce material waste. Design options include full-color digital printing, customizable interior prints, embossing, foil stamping, and spot UV finishes to add flair and sophistication. Businesses can select additional features such as padding inserts or dividers for extra protection of fragile goods. Our design team collaborates closely to create packaging that elevates your product presentation and meets logistical needs efficiently.

Premium Materials & Sustainability

Sustainability is a cornerstone of our custom mailer boxes. We source durable, 100% recyclable corrugated cardboard, paired with environmentally responsible water-based or soy-based inks. The boxes’ design minimizes tape and plastic use, promoting eco-friendly shipping practices. By choosing our sustainable packaging, brands demonstrate environmental stewardship, appealing to conscious consumers and adhering to regulatory requirements. Our mailer boxes combine durability with eco-conscious materials to reduce environmental impact while maintaining superior protective qualities.

How Do Custom Mailer Boxes Ensure Product Protection?

Protection is integral to every aspect of our mailer designs. High-strength corrugated cardboard absorbs shocks and resists crushing under moderate loads, ensuring products remain intact. Self-locking mechanisms secure boxes whilst preventing accidental openings or tampering. Custom internal inserts stabilize products, reducing movement and damage risk during transit. Moisture-resistant coatings safeguard contents from humidity and external contaminants. These protective measures lower product returns and improve customer satisfaction, reinforcing your brand’s reliability and professionalism.

Affordable Packaging Solution Without Compromising Quality

Little Rock Packaging offers competitive pricing on customizable mailer boxes by leveraging efficient manufacturing and bulk sourcing strategies. Flexible minimum order quantities accommodate businesses of all sizes, from small startups to large-scale enterprises. Durable packaging lowers costs associated with damage, replacements, and returns, optimizing profitability. Our mailers provide high value by combining unrivaled product protection, aesthetic excellence, and sustainability at an accessible price point, ensuring excellent return on investment.

Versatile Use Cases Across Different Industries

Our custom mailer boxes suit a broad spectrum of product categories, including beauty, food, apparel, electronics, and subscription services. This versatility allows brands to maintain consistent packaging standards across multiple industries and sales channels—retail, direct-to-consumer, and wholesale. Little Rock Packaging’s mailers support dynamic market demands by delivering secure, attractive, and eco-friendly packaging that fosters growth and elevates consumer experience.

Frequently Asked Questions

Custom Printed Packaging & Orders

How can I request a quote for my project?

You can receive a personalized price quote by:

  • Visiting our ‘Request a Quote’ page or submitting a request directly from any product page.
  • Reaching out to our sales team via our online chat feature.
  • Sending an email with your project details to sales@littlerockpackaging.com.
  • Calling us directly.

For most inquiries, we typically provide a pricing quote within 2–4 business hours. However, complex projects may require 24–48 hours for a detailed quotation. Your account manager will keep you updated throughout the process.

What is the process for modifying or canceling an existing order?

Modifications to your order can be made before production begins. Depending on the changes, a revised estimate may be required, and you will receive an updated quote accordingly.

Please note that custom-printed products are unique and cannot be repurposed. In some cases, cancellations may be possible at different production stages, but cancellation fees will apply based on the work already completed. Our customer service team will inform you of any associated costs. Once an order moves past the production preparation phase and enters the shipping stage, it can no longer be canceled.

Where can I have custom boxes made?

We are a dedicated packaging company providing custom packaging solutions for businesses of all sizes. Our team specializes in designing tailored packaging that meets your unique needs and enhances your brand’s identity.

Are there alternative materials to cardboard for making custom boxes?

Yes, we provide a variety of materials for creating custom boxes, including paperboard, rigid packaging, and more, allowing businesses to choose the best option for their needs.

What steps are involved in receiving my print orders?

The process of receiving your custom print orders includes the following stages:

  • Project consultation and design discussion
  • Quote preparation and approval
  • Artwork creation and review
  • Sample production (upon request)
  • Manufacturing
  • Shipping

A dedicated account manager will guide you through each step, and our sales support team is available to provide additional details and address any inquiries.

How are custom boxes made?

We provide tailored packaging solutions designed to meet the specific requirements of businesses. Our experienced design team utilizes advanced technology to create custom boxes in various shapes, sizes, and materials.

Where can I purchase custom boxes in the USA?

Little Rock Packaging is a U.S.-based packaging company that specializes in custom packaging solutions for businesses nationwide. We design and manufacture custom boxes to meet the unique requirements of each client.

What are custom packaging solutions?

Custom packaging solutions are specialized packaging options tailored to the unique needs of a business. Our solutions are designed to enhance brand identity and improve the overall customer experience.

Production and Shipping

Can I request samples before placing a bulk order?

Yes, custom-printed samples are available upon request. For a small sampling fee, you can receive a hard copy of your specific project. Alternatively, you may request a free sample from our previously printed products.

Do you ship print orders internationally?

Yes, we offer worldwide shipping. If you have specific requests, please communicate them with your account manager. Keep in mind that international orders may be subject to additional shipping charges, customs fees, and taxes.

How can I cut and fold cardboard to make a box?

Our advanced technology and specialized equipment allow for precise cutting and folding of cardboard to create custom boxes tailored to business needs. The pre-made creases ensure easy and accurate folding for final assembly.

How long does delivery take after manufacturing is complete?

Orders are typically delivered within 3–4 business days after production is finished. Your account manager will keep you informed about your project's progress throughout both the manufacturing and delivery phases

What materials are best for making a custom box?

We offer a variety of materials for creating custom boxes, including cardboard, corrugated board, and more. Additionally, you can enhance your packaging with unique features such as embossing, debossing, and foil stamping.

How can custom packaging help reduce shipping costs?

Custom packaging can lower shipping costs by ensuring that boxes are designed to fit products precisely, minimizing empty space and reducing unnecessary shipping expenses.

We specialize in manufacturing a wide range of custom packaging solutions with diverse designs and customization options.

Little Rock Packaging also caters to wholesalers and white-label manufacturers, offering packaging in various sizes and designs tailored to client specifications.

Custom Designing and Art

How do I measure the dimensions of a custom box?

Little Rock Packaging’s design team assists businesses in determining the correct box dimensions by measuring the product’s length, width, and height. An additional margin is added to account for the thickness of the packaging material, ensuring a perfect fit.

How can I make my custom box look more professional?

Our expert design team can enhance the professionalism of your custom boxes by incorporating advanced printing techniques and premium materials. We ensure that each box not only meets high-quality standards but also strengthens your brand identity.