If you’ve ever ordered something online, the odds are that you’ve received a custom mailer box before. But what is a custom mailer box, and why is it dominating the packaging industry? Here’s what you need to know: 

What Is a Custom Mailer Box?

A custom mailer box is a stylish and sturdy box that’s perfect for ecommerce and subscription packaging. These boxes are designed to be shipped entirely on their own with no additional components, thanks to smart features like dust flaps that protect contents. 

Custom mailer boxes provide optimal protection for all sorts of ecommerce and subscription products thanks to E flute corrugated cardboard that’s about 1.5 millimeters thick. 

Why Use a Custom Mailer Box?

Here are some reasons why you should consider using a mailer box for your business:

1. Mailer Boxes Are Customizable

Mailer boxes are customizable to meet your packaging needs. For example, you can customize the size of mailer boxes to fit your products. 

You can also choose from various paper and printing options to create a mailer box that makes sense for your business and products. From there, you can design your mailer box to fit your brand aesthetic by incorporating your brand name, logo, colors, fonts, and more. 

2. Mailer Boxes Are Versatile

Mailer boxes are extremely versatile and can be used to ship your products no matter what they are safely. For example, custom mailer boxes are great for shipping skincare products in custom inserts. Custom mailer boxes are also great for shipping food items for subscription packages. 

You can even use custom mailer boxes to ship more delicate items like jewelry and glassware so long as you also incorporate the proper protective elements like filler, insets, dividers, bubble wrap, etc. 

3. Mailer Boxes Are Secure

Mailer boxes are designed to be completely secure thanks to dust flaps that essentially act as a “lock” on the box. As a result, mailer boxes provide you with a safe and convenient way to ship your products to your customers. 

4. Custom Mailer Boxes Are Actually Very Affordable

Custom mailer boxes may look fancy and expensive, but they are actually surprisingly affordable. This is because mailer boxes are made using low-cost raw and recycled materials. 

Mailer boxes are also a popular and common packaging product, so according to the basic laws of supply and demand, increased supply helps drive costs down. 

Finally, mailer boxes can usually be ordered in bulk, which may also help you achieve a lower rate.

5. Using Mailer Boxes is a Way to Go Green

The production of a mailer box is considered extremely “green” and environmentally friendly since mailer boxes are largely made from recycled materials. 

Additionally, you can recycle mailer boxes after use, and like other types of cardboard packaging, they can be reused and recycled up to seven different times.

Not only does this help your business take a stand as a “green” business, but it can also help you win more customers too. According to a study, 66% of all respondents and 75% of Millennial respondents say they consider sustainability when purchasing. Furthermore, 72% of respondents say that they’re actively buying more environmentally friendly products than they were five years ago and that they’re willing to pay more for these types of products and packaging. 

6. Your Customers Find Custom Boxes Exciting

The design of a custom mailer box makes the customer feel like they’re opening a present when they open the box. As a result, you can provide an exciting unboxing experience for your customers. 

You can further enhance the unboxing experience and boost customer loyalty by incorporating packaging extras like custom inserts, filler paper, and handwritten thank-you notes.

Where to Get a Custom Mailer Box?

Based on what we’ve learned about custom mailer boxes so far, it should come as no surprise that these boxes are dominating the ecommerce and subscription industry. But where can you get these boxes? With a custom packaging provider, of course! 

What to Look for in a Custom Packaging Provider?

Not all packaging providers are created equal. Here are some things to look for in a custom packaging provider to make sure that you receive the best quality mailer boxes

  • Experience: You want to work with a packaging provider that has plenty of experience in the packaging industry. Box Genie is part of a company with 45 years of packaging experience and is family-owned and operated. 
  • Reputation: You want to work with a packaging provider that has a good reputation with positive reviews from clients. Box Genie has worked with over 2,000 brands, big and small, to meet their packaging needs, including Black + Decker, Canon, Bose, and more. 
  • Efficiency: You want to work with a packaging provider that can provide you with your packaging materials in a timely manner. Many packaging providers produce and print their boxes overseas, which translates into lengthy turnaround times.
However, Box Genie ships orders from a US-based warehouse located in the Midwest. As a result, Box Genie can ship orders seven to ten days after confirmation. 
  • Sustainability: You want to work with a packaging provider that shares your same concerns about the environment and sustainability. Box Genie’s products are made with odorless water-based inks that pass food-safety standards with zero UV-reactive chemicals and produce zero hazardous air pollutants. Furthermore, Box Genie’s corrugated material contains the highest degree of recycled content allowed by the paper industry’s standards. Last but certainly not least, this corrugated material is locally sourced, which contributes to a lower carbon footprint. 
  • Quality: You want to work with a packaging provider that provides you with packaging materials of the highest quality. Box Genie provides customers with professional quality printing and packaging solutions that you will love and that will impress your customers. 
  • Customer service: You want to work with a packaging provider that is always available to answer your question or address any concerns. You can quickly speak to a representative at Box Genie by phone, email, or live chat. 
  • Ease of use: You want to design and order packaging products from your packaging provider easily. Box Genie’s website is extremely user-friendly so that you can get pricing information, design your packages, and check your order status. 

How to Design a Custom Mailer Box?

  1. Choose your dimensions
  2. Choose your paper type
  3. Choose your printing options
  4. Choose your quantity
  5. Design your box online or send in your box design

Here are the five steps to designing a custom mailer box

Step 1: Choose Your Dimensions

The first step involves choosing your dimensions. When you work with a custom packaging provider like Box Genie, you’re able to enter exact measurements that are then rounded up to the nearest quarter of an inch. 

That way, you can have complete confidence that your custom mailer box will fit your products exactly how you want them to fit. 

Step 2: Choose Your Paper Type

The second step involves choosing your paper type. There are three different paper types from Essential White, Magic White, and Kraft. Essential White is a classic white corrugated cardboard with a satin finish. Essential White works with all colors and can effectively showcase your brand logos, colors, fonts, and other design elements.

Magic White is a premium white corrugated cardboard with a glossy finish. Magic White products photo-quality high-definition printing for a smooth and luxurious look. 

Kraft is a natural brown matte corrugated cardboard that works well with dark colors and is extremely eco-friendly. However, it’s important to note that you cannot use white ink on Kraft paper. 

Step 3: Choose Your Printing Options

The third step involves choosing your printing options. There are also three different printing options: one-sided printing on the outside, one-sided printing on the inside, and two-sided printing on both sides. 

Box Genie offers four-color printing that covers a wide range of colors that show up beautifully on high-quality corrugated cardboard. 

Step 4: Choose Your Quantity

The fourth step involves choosing your quantity of boxes. Keep in mind that higher-order volumes may be eligible for volume discounts. 

Often, it makes sense to order your boxes in bulk, so you don’t have to panic when you’re running low and need to reorder and receive them quickly. 

If you do need your boxes quickly, Box Genie offers fast turnaround times in addition to two and three-day shipping with UPS. 

Step 5: Design Your Box Online or Send in Your Design

The fifth and final step involves designing your custom mailer box. If you’re creating your design from scratch, you can get creative juices flowing in Box Genie’s Design Studio. 

This tool allows you to design each element of your box in real-time. However, if you already have an existing design you want to use, you can simply attach it with your order, and the experts at Box Genie will take care of the rest. 

What Are the Alternatives to a Custom Mailer Box? 

Although a custom mailer box offers a whole host of benefits, it might not be right for every brand and every product. The best alternative to consider is shipping boxes.

Shipping Boxes

Box Genie also offers a shipping box similar to the classic square cardboard box. However, with Box Genie, you can customize your shipping box's dimensions, design, and printing options to meet your unique needs. 

Like a custom mailer box, custom dimensions for a shipping box are rounded up to the nearest quarter of an inch. 


So hop on the custom mailer trend by designing your box with Box Genie today. If you need any assistance along the way, feel free to reach out to a representative for personalized packaging guidance. 


Most Consumers Want Sustainable Products and Packaging | Business News Daily

How to Create an Unforgettable Unboxing Experience for Your Customers | Small Business Trends

Nine Factors to Consider When Creating the Perfect Product Packaging | Forbes

Trusted by top brands worldwide. Dedicated to smaller businesses like yours.

Over 2,000 brands trust us to help them grow and build successful businesses. Find out how custom packaging can work to help take your brilliant brand to the next level!

  • Black & Decker logo
  • Bose logo
  • Canon logo
  • Ecologic logo
  • Sergeant's logo

“They can’t be beat for price, speed, and quality. We trust them with all our packaging needs!”

Megan D., CEO at SSBD

“They can’t be beat for price, speed, and quality. We trust them with all our packaging needs!”

Megan D., CEO at SSBD

Ready to design your own box?

Start building your custom box now to see a preview of how it will look!