Custom Mailer Packaging

Product packaging is all about product protection and presentation. But doing all this, we must also make sure that the packaging style is convenient and functional. In this comes mailer packaging that is manufactured with premium quality materials and has the most functional style. Custom Boxes Market is one of the top manufacturers of mailers in the USA and is renowned due to the following features of its packaging: 

• Easy to use 
• Durable 
• Sustainable 
• Affordable 
• Free from the hassle of gluing or tapping 
• Attractive 

From simple to custom luxury mailer boxes, we have all the options at your disposal so you can remain famous for its product presentation and protection.

What Is Custom Mailer Packaging?

Maile packaging boxes are one of the most functional and durable packaging boxes that are used in shipping and the retail market. Their common applications are in the shipping of small to medium-sized products. Custom mailer boxes have self-sealing tabs or flaps that allow the easy opening and closure of the packaging. There are several types of mailer boxes based on the material, as well as slight variations in style. 

Standard Tuck Top Mailer Box: These mailer boxes have a front flap that tucks into the box and are easy to assemble with catchy visuals. These boxes are commonly used as electronic boxes or subscription boxes. 

Roll End Tuck Front Mailer Box: Custom roll-end mailer boxes have a locking tab in front of the boxes for a more secure closure. These boxes are used for slightly heavier items and are commonly applied as e-commerce boxes. 

Roll End with Locking Cover Mailer Box: These boxes have an extra locking lid to enhance the protection of the product. For luxury goods and to give a display appeal, roll ends with locking cover mailer boxes are used. 

Front Lock Mailer Box: Front lock mailers have locking wings that allow a secure lid insertion in the front panel. This style is used for retail packaging and offers tamper resistance without the need for taping.

Full Overlap Mailer Box: In these boxes, the top and the bottom flaps overlap completely. This doubles the material thickness and is a perfect option for heavy items. 

Manufacturing of Mailer Boxes

When you choose our company as your packaging partner, you select the freedom to get boxes in any design you want. We use one of the highest quality packaging materials and manufacturing processes. The following steps are involved in the production and material selection of boxes: 

Material Selection

The main material in the manufacturing of custom mailers is corrugation, but other paper-based materials are also used. The choice of material determined the durability of boxes and how the printed design would look. There are multiple types of material that can be used to manufacture these boxes, such as:

• Custom cardboard mailer boxes
• Custom corrugated mailer boxes
• custom double-sided mailer boxes with corrugation 
• Custom kraft mailer boxes
• Rigid mailer boxes 

Die-Cutting

We use a rotary or a flatbed die cutter to create a die line. This is done to cut the material into the precise shape and size of the box with fold lines and flaps. The following cuts are involved in the process of simple or custom mailer boxes with inserts: 

• Straight cuts
• Perforations
• Scoring for folds
• Slots for locking tabs

Printing Process

Custom printed mailer boxes are designed in such a way that they not only work as protective packaging but also as a promotional tool. These boxes give your product a classy look and elegant presentation, so the customers can never forget your brand. There are several printing options that we use for custom mailer boxes with a logo:

• Flexographic printing is used for simple designs and large runs of boxes 
• Lithographic printing gives high-resolution designs for large runs 
• Digital printing is an excellent option for short runs and variable designs

Coatings For A Catchy And Protective Outer Surface 

Paper-based materials have only one drawback, which is the lack of moisture resistance. To overcome this drawback, we apply post-printing coatings on the boxes. These coatings give an elevated look to the packaging and help brands get the most out of the box presentation. 

Whether you need custom mailer pr boxes or jewelry packaging, we have come up with all the options of coatings at your disposal. These coatings also protect the printed artwork on the boxes from fading and scratches. 

Add-Ons

Luxury mailer packaging is available with the combination of coatings and add-ons. Add-ons are the most effective solution in enhancing the overall appearance of the boxes while increasing the functionality of the packaging. We have several options of add-ons that help you get packaging with the most remarkable appearance.

• Spot UV
• Foil stamping
• Embossing
• Debossing
• Die-cut windows 
• Inserts 

Folding And Gluing

A folder or gluer is used in the packaging to fold the printed diet cut sheet along the creases. These folds are glued at the side seams to give the boxes a compact structure. To reduce the overall time of production, we use automated machines for mass production. The result of this process is pre-glued mailer boxes that are ready for assembly. 

Contact Us! 

Get your mailer packaging boxes manufactured by Custom Boxes Market in the USA and start excelling your product presentation. We give affordable prices and premium quality customization options to ensure the uniqueness of your brand and the protection of your product. So get a quote today and receive your boxes in no time.