Corrugated Mailer Boxes UK | Mailer Boxes Co

About our box

Corrugated Mailer Boxes, made to your size

Corrugated board is what gives a mailer box its strength. A fluted middle layer sits between two flat liners, creating a light but rigid wall that resists crushing in courier vans and sorting centres. Our corrugated mailer boxes use that strength in a neat, self-locking design that you can print with your brand.

Why choose our corrugated Mailer Boxes

Choosing the right flute is a balance between protection and print quality. E-flute is thin, smooth and prints sharply, ideal for most products up to a few kilos. B-flute is thicker and more cushioning for heavier or more fragile items. We will help you choose.

Popular uses

Heavier products and bundles
Fragile items that need cushioning
High-volume online orders
Wholesale and trade shipments
Subscription boxes

Materials, print and finishes

E-flute, B-flute or double wall board
Kraft or white outer liner
Recyclable in UK kerbside collections
Flat-packed for easy storage

Not sure which board you need? Tell us what you are shipping and roughly how much it weighs, and we will recommend a board in your quote.

Sizes and dimensions

Every order of corrugated Mailer Boxes is made to your dimensions in millimetres (length × width × height). Not sure of the size? Choose “Not sure — suggest a size” in the options above and tell us what you are packing, and we will recommend dimensions and show them in your mock-up. You can also order several sizes in the same design to cover your whole range.

Related packaging

Comparing options? Take a look at Double Wall Mailer Boxes, Cardboard Mailer Boxes and Shipping Boxes, or browse all custom mailer boxes and our wider custom packaging range.

How to order

Choose your size and options above and request a free quote. We reply within 24 hours with your price and a free 3D mock-up, and nothing is printed until you approve it. Orders are delivered across the UK in 12–14 working days; see our delivery information. The “From” price is our bulk price per unit, excluding VAT, and larger quantities bring the unit price down. Selling clothing too? We also make custom apparel to ship in your boxes.

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Specifications

Board	E-flute (≈1.5 mm), B-flute (≈3 mm) or double wall
Style	Self-locking mailer, tape-free
Print	CMYK and Pantone, outside, inside or both
Finishes	Matte, gloss or soft-touch; foil, spot UV, embossing
Size	Made to your inside dimensions (mm)
Recyclable	Yes, with UK paper and card recycling
Minimum order	Low minimums
Delivery	12–14 working days after approval, UK-wide
Category	Custom Mailer Boxes

New · Custom Apparel

Fill your boxes with your own merch

Hoodies, tees, sets, caps and socks — cut and sewn to your design from 20 pieces per style, packed in your boxes and delivered together.

Explore custom apparel

How it works

Tell us your box
Size, print and quantity — or ask us to suggest a size.
Free 3D mock-up
See your design on the box before anything prints.
We print and make
Printed, die-cut and quality checked.
Delivered flat
Tracked UK delivery in 12–14 working days.

Questions about Corrugated Mailer Boxes

What is the difference between E-flute and B-flute?

E-flute is about 1.5 mm thick and gives a smooth surface for sharp print. B-flute is about 3 mm thick and offers more cushioning and stacking strength.

Are corrugated mailer boxes recyclable?

Yes. Corrugated board is one of the most widely recycled packaging materials in the UK.

How much do corrugated mailer boxes cost?

The “From” price on this page is our bulk price per unit, excluding VAT. Your exact price depends on size, quantity, print and finish, and we send it with a free mock-up within 24 hours.

How long does delivery take?

12–14 working days after you approve your mock-up, with tracked delivery anywhere in the UK.