Corrugated Mailer Boxes

Little Rock Packaging’s Corrugated Mailer Boxes provide robust, lightweight, and eco-friendly shipping solutions. Customizable in size, design, and print, these boxes ensure superior protection for delicate and heavy items, while enhancing brand visibility and reducing shipping costs.

Add-Ons

Elevate your brand image with our premium Add-Ons! Choose from glossy or matte lamination, spot gloss, foiling, embossing, debossing, and more to make your product packaging truly stand out.

Gloss Finishing

Provide a shimmery look to your packaging.

Matte Finishing

Provide a shimmery look to your packaging.

Gold Foiling

Creates reflective and luxurious looks.

Silver Foiling

Produces reflective and sophisticated aesthetics.

Embossing

Raise graphic elements for a tactile effect.

Debossing

Recesses graphic elements for a subtle yet impactful design.

Holographic

Gives a three-dimensional and mesmerizing look.

Spot UV Coating

Makes printed elements vibrant & eye-catching.

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 Corrugated Mailer Boxes are specially designed for secure shipping and protection of products during transit. Crafted from corrugated cardboard, these mailers combine durability with a lightweight structure, providing strength and shock absorption to safeguard contents from damage. Their design is suited for a wide range of industries, including electronics, cosmetics, apparel, and accessories. Fully customizable to fit products perfectly, these boxes help businesses reduce shipping expenses and deliver impressive branded experiences.

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

Corrugated mailer boxes offer a unique combination of protection and convenience. Their corrugated construction consists of one or more layers of fluted cardboard sandwiched between liners, which absorb impact and resist crushing. Compared to traditional boxes, mailer boxes are easier to assemble, allowing quicker packing and shipping. They often feature self-locking or tuck-in designs that securely close without adhesives or tape, reducing packing time while enhancing security. Custom printing transforms these functional boxes into brand ambassadors, communicating professionalism and trust to customers before the package is even opened.

Customizable Features for a Perfect Fit

Little Rock Packaging offers extensive customization options to tailor corrugated mailer boxes for specific product dimensions and shipping requirements. You can select from single-wall, double-wall, or triple-wall constructions based on cargo weight and fragility. Various flute types (A, B, C, E, F) offer cushioning and print finish options for visual impact. Mailer styles include regular slotted container (RSC), roll end tuck, and auto-lock bottom designs to suit operational preferences. High-resolution printing with unlimited color options, gloss or matte laminations, and spot UV or foil stamping are available to create eye-catching packaging. Optional inserts or dividers provide additional product organization and protection.

Premium Materials & Sustainability

Sustainability drives the materials and processes at Little Rock Packaging. Our corrugated mailer boxes are made from FSC-certified recycled cardboard, using environmentally friendly inks and coatings. These recyclable and biodegradable materials contribute to reduced environmental impact while maintaining strength and durability. Lightweight construction reduces transportation energy use and lower shipping costs. Our eco-friendly packaging solutions support brands in meeting consumer demand for sustainable products and complying with environmental regulations without compromising protection or branding quality.

How Do Corrugated Mailer Boxes Ensure Product Protection?

Protection is integral to the design of our corrugated mailer boxes. The fluted corrugated medium acts as a shock absorber, guarding against impacts, crushing, and vibration damage during transit. The durable liners resist punctures, moisture, and wear. Customized inserts or cushioning solutions can be incorporated to prevent movement and protect fragile items. Secure closures such as tuck-in flaps or auto-lock bottoms maintain box integrity, preventing accidental openings and product loss. These protective features reduce breakage, returns, and customer dissatisfaction while ensuring products arrive in perfect condition.

Affordable Packaging Solution Without Compromising Quality

Little Rock Packaging offers competitively priced corrugated mailer boxes designed to maximize protection while minimizing costs. Efficient production methods, bulk sourcing, and flexible minimum order quantities help small to large businesses access premium packaging. The lightweight mailer design reduces shipping fees, and durable construction lowers losses due to damage. Our versatile mailers deliver excellent value by combining protection, sustainability, and branding within budget, producing measurable ROI for your shipping needs.

Versatile Use Cases Across Different Industries

Corrugated mailer boxes serve a diverse range of industries including e-commerce, retail, pharmaceuticals, electronics, cosmetics, and luxury goods. Their adaptability for various product sizes and shipping routes makes them an essential packaging choice. Suitable for direct-to-consumer shipments, subscription boxes, and wholesale distribution, these mailers enable businesses to provide consistent, secure, and branded packaging experiences that satisfy modern consumer expectations.

SBS C1S

SBS C2S

CCNB

Fully Recycled CCNB

Clay Coated Kraft Back (CCK)

White Kraft

Natural Brown Kraft

Uncoated Unbleached Kraft (UUK)

Black Kraft

Textured

Metallic Paper

Holographic

BOX FEATURES

3 Flaps Tuck Top Lid

Cherry Lock

Roll End Tray

Tear Strip

Tuck Top Lid

Perforation

PRINTING METHODS

Offset Print

Digital Print

UV Print

Scodix Digital Enhancement

INKS

Water-based Inks

Soy Vegetable Based Inks

Fluorescent Color Inks

Oil Based Inks

Pantone

Pantone Metallic

FINISHINGS

Aqueous Coating

UV Coating

Spot Gloss UV

Anti-scratch lamination

Soft Touch Coating

Varnish

Lamination

Soft touch / Silk Lamination

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.