Mailer Boxes

If you ship products to customers, your box is your storefront at the doorstep. Little Rock Packaging builds custom mailer boxes to your exact product dimensions, from the board and print to the finish. Pick your size, material, and artwork, then order in wholesale quantities built for ecommerce fulfillment, subscription services, and retail-ready shipping. Every box is engineered to survive carriers and arrive looking like your brand meant it.

Your Brand Arrives Before the Product Does

A plain brown shipper protects the product and nothing else. A printed mailer turns every delivery into a branding moment that subscribers photograph, customers remember, and gift recipients keep. Mailers also cut down on damage claims, since corrugated walls absorb the bumps that crush thin cartons. The wrong size box wastes filler and freight money, while the right size ships tight and looks deliberate. Precise dimensions keep products from shifting in transit, and full-color print turns a shipping box into shelf-worthy packaging.

Box Styles Built Around Your Shipments

Products come in different shapes and weights, so one mailer size rarely fits a whole catalog. Our custom mailer boxes are made to your exact dimensions, from small subscription refills to large multi-item orders. Popular styles include roll-end tuck front mailers for clean retail presentation, auto-lock mailers for fast packing lines, and corrugated trays with lids for heavier goods. Self-sealing strips speed up fulfillment, and tear strips give customers a clean, tool-free open.

Specifications

Material We Use

Corrugated board gives mailers their shipping strength, with flute profiles matched to your product weight. Kraft corrugated suits eco-conscious brands with a natural look, and white corrugated offers a bright face for full-color print. Heavier double-wall grades protect fragile or dense items on long routes.

Inks

Full-color CMYK printing handles photographic imagery, patterns, and bold graphics in sharp detail. Pantone-matched spot colors keep your branding consistent across every shipment. Printing can run on the outside only or inside and out, and inside print turns the unboxing into a second branding moment.

Finishing

Matte lamination reads refined, gloss lamination makes colors pop at the doorstep. Foil stamping, embossing, and spot UV lift your logo off the surface for a premium unboxing. A scuff-resistant coating keeps printed mailers looking clean after rough handling by carriers.

Add-Ons

Custom inserts, dividers, and partitions keep multi-item orders organized in transit. Tissue liners and crinkle fill add cushioning and presentation, and branded tape or seals carry your logo across the closure. Die-cut handles help with heavier retail-ready mailers.

Why Choose Us

Overseas suppliers can leave you with missed launch windows, inconsistent colors, and revisions that drag on for weeks. We design and produce packaging for US-based brands, so your boxes meet US carrier requirements and your timeline. Order quantities stay flexible for startups and growing ecommerce labels, and per-unit pricing improves as your volume grows. Adjustments to your dieline or artwork stay simple with a team that understands your business.

We Are a Mailer Box Specialist

Mailer packaging is a focused craft, and we treat it that way. Share your product sizes and monthly ship volume, and we will build the box around them.

Get Custom Mailer Boxes Wholesale

Whether you need a small test run or a large fulfillment rollout, we have the capacity to deliver mailer boxes made to measure for your brand. Request a free quote today and get packaging that arrives like an event.

Frequently Asked Questions

Are custom mailer boxes recyclable?

Yes. Corrugated mailers are widely accepted in curbside recycling programs, and water-based printed boxes recycle easily. Heavy lamination can complicate recycling, so if sustainability is part of your brand story, ask about uncoated or recyclable finish options when you request your quote.

Can I print on the inside of the mailer?

Yes. Inside printing is one of the most popular mailer upgrades. A pattern, message, or coupon code on the interior turns the unboxing into a surprise that customers photograph and share. It costs more than outside-only print, but brands with subscription or gift customers find it pays off in repeat orders.

What size mailer should I order?

The best size fits your product snugly with room for cushioning and inserts. Oversized mailers waste filler and raise freight costs, while tight mailers risk damage. Share your product dimensions and any inserts when you request your quote, and we will size the mailer around them.

Do mailers need tape to close?

Not always. Many mailer styles close with locking tabs that hold without tape, and self-sealing adhesive strips speed up high-volume packing lines. Tape-free designs save time and give a cleaner look at the doorstep. Your quote will note the closure style for the box you choose.

Can mailers handle fragile products?

Yes, with the right combination of board and inserts. Double-wall corrugated adds crush strength, and custom inserts or partitions lock fragile items in place so they cannot collide. Share your product and its fragility when you request your quote so we can spec the protection you need.