Types of Mailer Boxes: 15 Styles Explained (and When to Use Each)
Kraft, white, double wall, ear lock, sleeved and more: 15 types of mailer box compared, so you can pick the right one for your products.
“Mailer box” covers far more than one style of box. The board, the closure and the way the box opens all change how well it protects your product and how it feels to unbox. Here are the main types of mailer boxes we make for UK brands, grouped by what they are made from, how they close and what they are for.
Mailer boxes by material
1. Kraft mailer boxes
Kraft mailer boxes use a natural brown board that looks honest and eco-friendly. They are the most cost-effective way to get a printed box, and a one-colour black or white logo looks sharp on them. Ideal for sustainable brands, food, coffee and handmade products.
2. White mailer boxes
White mailer boxes give the brightest, most accurate full-colour print. If your brand uses pastels or bright colours, white board is the way to get them right.
3. Corrugated mailer boxes
Most mailers are corrugated, but corrugated mailer boxes in thicker B-flute board are the choice when cushioning matters more than a thin profile.
4. Double wall mailer boxes
double wall mailer boxes combine two layers of flute for heavy, fragile or high-value products such as glassware, ceramics and bundles.
5. Cardboard, boxboard and chipboard mailers
cardboard mailer boxes are the everyday all-rounder. boxboard mailer boxes use a thin, smooth single sheet for light products and fine print, and chipboard mailer boxes show off a dense recycled board for an eco look.
Mailer boxes by closure
6. Ear lock mailer boxes
ear lock mailer boxes have small “ears” on the lid that lock into the side walls. The closure is secure, tape-free and reusable, which is great if customers keep the box.
7. Tab lock mailer boxes
tab lock mailer boxes close with a tab that slots into the front panel, giving a clean front edge and a satisfying click.
8. Tuck top mailer boxes
tuck top mailer boxes use a long front flap that tucks inside the box. They are quick to pack and open neatly.
9. Sleeved mailer boxes
sleeved mailer boxes add a printed sleeve that slides off before the lid opens. Use one box with different sleeves for each product or season.
Mailer boxes by purpose
10. eCommerce and shipping mailers
ecommerce mailer boxes and shipping boxes are built for daily fulfilment: strong, fast to assemble and sized to cut void fill. postal boxes are designed to fit Royal Mail and courier size bands.
11. Mailer boxes with inserts
mailer boxes with inserts hold bottles, jars and gift sets in place with card, corrugated or foam cut-outs.
12. PR and marketing mailers
PR mailer boxes and marketing kit mailer boxes are designed for influencer seeding, press kits and sales packs, with inside print and inserts that make the unboxing worth filming.
13. Luxury and gift mailers
luxury mailer boxes add soft-touch lamination, foil and embossing, while mailer gift boxes are made to be posted straight to the person receiving the gift.
14. Small and flat mailers
small cardboard mailer boxes, book mailer boxes and plastic-free paper padded mailers keep small items safe, and many can be made to fit through a letterbox.
15. Specialist mailers
Some products need a specific shape: hat mailer boxes protect caps, bath bomb mailer boxes stop bath bombs crumbling, doughnut mailer boxes keep treats in place and custom postal tubes carry posters and prints.
Which type should you choose?
| If you need… | Choose |
|---|---|
| Lowest cost with a branded look | Kraft mailer boxes with a one-colour logo |
| Bright, accurate brand colours | White or coloured mailer boxes |
| Heavy or fragile products | Double wall mailer boxes, often with an insert |
| A premium unboxing | Luxury, sleeved or PR mailer boxes |
| Cheaper postage for small items | Small cardboard mailers or book mailers in Large Letter size |
Still deciding? Our mailer box size guide helps you get the dimensions right, and you can compare every style in our custom mailer boxes range. When you’re ready, request a free quote and we’ll send a 3D mock-up within 24 hours.
Print and finish options for every type
Whichever style you choose, the print and finish make it yours. Every mailer can be printed outside only, or inside and outside for a reveal when the lid opens. Choose matte lamination for a modern look, gloss to make colours pop, or soft-touch for a velvety premium feel. Add foil stamping in gold, silver or rose gold, spot UV on your logo, or embossing for a raised, tactile finish.
A simple rule: spend on one standout detail rather than every upgrade. A kraft box with a foil logo, or a white box with full inside print, looks more considered than a box covered in finishes.
Matching the box to the product
Single-product brands often go for product mailer boxes made to fit one hero product exactly. Brands with a range usually settle on two or three sizes of ecommerce mailer boxes in the same design. Seasonal campaigns switch to christmas mailer boxes or holiday mailer boxes without changing size, so the packing bench doesn’t change. If you need a bold brand colour, coloured mailer boxes are flood-printed in your exact shade.
Frequently asked questions
What is the most common type of mailer box?
The corrugated roll-end tuck-front mailer, usually in kraft or white board. It is strong, tape-free and works for most eCommerce products.
Which mailer box closure is most secure?
Ear lock and tab lock mailers give the firmest tape-free closure. Add a seal sticker for tamper evidence.
Can I mix box types in one order?
Yes. Many brands order a few styles or sizes with the same artwork. Add each one to your quote request.
Are all these mailer boxes recyclable?
All our cardboard and paper mailers can go in UK household paper and card recycling. Foam inserts and plastic laminations should be separated first.
What is the difference between a mailer box and a shipping box?
A mailer box is a one-piece folding box with a hinged lid that locks without tape, designed to look good when opened. A traditional shipping box is a plain carton sealed with tape.
Which mailer box is best for small businesses?
Kraft mailer boxes with a one-colour logo give the best balance of cost and brand impact for most small businesses.
