The Ultimate Guide to Shipping Products in Custom Mailer Boxes

• William Brooks
• Jun 29, 2025

Packaging is the first thing that usually get noticed on retail shelves but what if your packaging doesn’t maintain overall safety and lacks aesthetic appeal, definitely unacceptable.

Shipping products in custom mailer boxes ensure utmost safety/ protection during transit. Not only these boxes provide better protection but also help you customise them in the way you want.

In this blog post, we are going to share everything you need to know about customised mailer boxes and how they maintain overall safety during shipping.

Importance of Shipping Products in Custom Mailer Boxes

Custom printed mailer boxes are characterised by its corrugated walls. The slight padding of box makes it an ideal choice for transporting fragile or glassware items that can prone to damage easily.

By shipping your branded items in mailer box packaging, you will be satisfied enough that items delivered to final destination safely. This builds customer trust and increase brand reputation.

Besides shipping items safely, one standout feature of these boxes are that it could be customised easily. Whatever you want to add or print on the box, all of them could be easily added.

What you Need to Look for in a Mailer Box Packaging?

When selecting mailer boxes for your brand’s packaging needs, here are some factors that deserve attention for safe shipping.

1. Paper Grades

Paper grade choice affects both aesthetics and overall durability. By choosing the right paper grade, you can maintain a balance between aesthetics and durability. Each grade is best for maintaining sturdiness but you need to go for one that you think works best for your product packaging.

2. Closures

The opening and closing lid of box should be easy to open or close. Whether you want to use adhesive strips, custom seals or interlocking flaps, effective closure method is ideal for safe transit and unboxing experience.

3. Printing

The printing quality and nature on your custom printed mailer box should match with brand’s voice. The clear and vibrant prints enhance brand visibility and communicate brand values. The printing choice is yours so choose wisely and keep your target audience in mind.

4. Finishes

Finishing touches matter. Matte, gloss or whatever you want to choose, think if it works with your product packaging or not. It’s like subtle details that can change your packaging from ordinary to extra-ordinary. You may also add ribbons, stickers or necessary labels to make it more user-friendly.

What Type of Mailer Box Should I Use?

When it comes to custom mailer boxes UK, there are 5 basic styles to choose from. Let’s take a look which works best for your brand.

1) Tab Locking

These boxes sell the most and that’s why we recommend the most. Many brands prefer to use this box style for keeping safety and creating memorable unboxing experience for customers. On the box lid, logos and branding look great while the locking feature features clean seal.

2) Regular Slotted Container

Each side of RSC box has a tab that folds over and seam is taped shut on the bottom and top. RSC boxes are best option when you want to ship heavyweight items or products that require deep box sizes. Many brands use these type of boxes when they want to pack fragile items.

3) Five-Panel Folder

The design of FPF box is very similar to RSC box. One main thing that makes this box different from RSC is it has an extra flap that reinforces the structural integrity. This design is best for long items like bat, hockey sticks and such other items.

4) One Panel Fold

One panel fold, by name suggests, a perfect mailer box style for slim or flat items like books, frames and prints. They are thin in nature and have some of the characteristics of a flat envelope mailer. This box will give a great look when you print several effects or things.

5) Trays

Trays by nature are not boxes but play an important role in transportation of plants, cans and other bottles. They are likely same to tab locking boxes but just miss the top closure. You can use trays even inside the mailer box packaging of any shape or style.

Final Thoughts!

Choosing the right box for shipping products in custom mailer boxes greatly depends on product type, aesthetic appeal and unboxing experience. As per your brand’s packaging needs, go for box that best matches with all factors that should be considered.

Need help in figuring out the best custom printed mailer box for your brand? Contact us anytime to get free quote. We feel proud in delivering top-notch custom printed packaging solutions at market competitive prices.