E-Commerce Mailers
The classic roll-end tuck-front box — sturdy, smart and perfect for online orders of every kind.
Mailer BoxesCustom printed corrugated mailer boxes engineered for postal and e-commerce protection
Self-locking corrugated mailer boxes printed with your branding — the packaging of choice for UK e-commerce and subscription brands. Strong enough to ship without tape, beautiful enough to feel like a gift.
Your specification. Your artwork. A clear quotation.
Consider the details
What is a mailer box and why do e-commerce brands use them?
A mailer box is a self-locking corrugated box that folds together without glue or tape, designed to be shipped directly through the post. UK e-commerce and subscription brands use custom printed mailer boxes because they survive courier networks without extra outer packaging, and they turn every delivery into a branded unboxing moment that customers share and remember. At QPack, custom mailer boxes start from just 100 units — and because the setup cost is the same whether you order 100 or 1,000, many brands choose to order 1,000 straight away to get 10× the stock for almost the same price per unit. Standard production is 5–7 working days.
- Self-locking design — no tape or glue needed for assembly
- Corrugated E-flute board protects contents through UK courier networks
- Full-colour printing outside and inside for a premium unboxing
- Royal Mail letterbox-friendly sizes available for subscription products
- Sizes
- Any bespoke sizeLetterbox to XL
- Board
- E-flute · B-fluteWhite · Kraft · Recycled
- Printing
- CMYK · PantoneInside & outside
- Finishing
- Matte · GlossSoft-touch · Foil
- Min. Order
- From 100 unitsSame unit price at 1,000 — most brands order 1,000
- Lead Time
- 5–7 working daysExpress available
Find your fit
The Right Mailer for Every Delivery
From letterbox-friendly slimline boxes to heavy-duty shippers — all fully branded, all made to order.
Subscription Boxes
Consistent, collectable branded boxes for monthly subscription services and product clubs.
Letterbox Boxes
Slimline mailers under 25mm deep that fit through a standard UK letterbox — no missed deliveries.
Luxury Mailers
Premium printed mailers with inside printing, tissue and inserts for high-end brands.
Heavy-Duty Shippers
Double-wall corrugated boxes for heavier or fragile products that need extra protection.
Box Inserts & Fitments
Custom-cut card or corrugated inserts that hold products securely and elevate presentation.
Printed Tissue & Extras
Branded tissue paper, stickers and thank-you cards to complete the unboxing experience.
Bulk / Wholesale
High-volume mailer production with serious cost-per-unit savings for growing brands.
A closer look
Mailer Boxes Built for UK E-Commerce
Around a quarter of UK retail sales now happen online — and for an online brand, the box is the first physical touchpoint your customer has. We make mailers that arrive intact, look brilliant and get shared.
Engineered for courier networks
E-flute and B-flute corrugated board tested to survive Royal Mail, Evri, DPD and every UK courier.
Inside & outside printing
Full-colour print on both faces — the inside lid is prime space for a brand message or QR code.
From 100 units — same unit price at 1,000
We accept orders from 100 units. Because the setup cost is fixed, the price per unit at 100 is almost identical to 1,000 — most brands go straight to 1,000 to get 10× more stock for barely any extra cost. Real savings start at 2,500+.
Sustainable by default
Corrugated board is one of the most recycled materials in the UK — FSC-certified and recycled grades available.
Sized to cut postage costs
We design to Royal Mail Small and Medium Parcel bands — the right size can save thousands a year in postage.
E-Commerce Packaging
Corrugated Mailers Engineered for Impact
Turn every delivery into a branded unboxing experience. High-strength E-flute board with edge-to-edge outside and inside full-colour printing.
E-Commerce Mailer Boxes That Wow On Arrival
Self-locking corrugated mailer boxes are the packaging standard for UK e-commerce, subscription boxes, and direct-to-consumer brands. Strong enough to withstand courier transit without external tape, and styled to create an unforgettable unboxing experience.
Mailer Box Highlights
- Self-Locking FEFCO 0427 Design: Assembles quickly without glue or tape.
- Corrugated Fluting: Sturdy E-flute and B-flute boards in White, Brown Kraft, and Recycled grades.
- Letterbox-Friendly Options: Slimline sizes under 25mm deep to pass Royal Mail Large Letter requirements.
- Full Interior Print: Print custom graphics, thank-you messages, and QR codes inside the lid.
Production & Workflow
Our 4-Step Packaging & Production Process
From initial container measurement and 3D CAD dielines to high-definition printing and tracked UK delivery.
Step 01 Share your brief
Send your product, dimensions, quantity and any artwork you have. Undecided details can be discussed.
Step 02 Agree the details
Review the proposed material, construction, artwork and quotation before confirming your order.
Step 03 Plan your delivery
Confirm the production schedule and delivery arrangements for your approved specification.
Step 04 Quality Inspection & Tracked UK Delivery
Every batch is inspected for structural crease squareness, adhesive seam integrity, and finish fidelity before secure dispatch with tracked mainland UK delivery.
Clear Answers
Frequently Asked Questions
Clear answers on sizing, minimum order runs, artwork proofs, board calipers, and free tracked UK delivery.
What is the difference between a mailer box and a shipping box?
A mailer box is self-locking and folds together without tape, with a built-in lid — designed to be shipped as-is and opened as a branded experience. A standard shipping box (like an RSC carton) needs tape to seal and is usually plain. Mailers cost slightly more per unit but double as both protection and presentation.
What is the minimum order for custom mailer boxes?
We accept orders from 100 units. However, because the setup cost is the same at any quantity, the price per unit at 100 is almost identical to 1,000 — so ordering 1,000 gives you 10× more stock for barely any extra total cost. Most brands go straight to 1,000 for this reason. Volume discounts then apply at 2,500, 5,000 and 10,000+ units.
How much do custom mailer boxes cost in the UK?
Pricing depends on size, board grade, print coverage and quantity. As a guide: Small mailer boxes (4×4×2 to 6×4×2 in) start from £0.95/unit at 1,000 units. Standard mailers (7×5×2 to 9×6×3 in) from £1.65/unit. Large mailers (10×8×4 to 12×9×4 in) from £2.65/unit. Prices per unit fall significantly at 2,500, 5,000 and 10,000 quantities. Request a free quote for your exact size.
Can you make letterbox-friendly mailer boxes?
Yes. We produce slimline mailers designed to fit through a standard UK letterbox (under 25mm deep), which means no missed deliveries and lower Large Letter postage rates for subscription and gifting brands.
Are mailer boxes strong enough to post without an outer box?
Yes — that is exactly what they are designed for. Corrugated E-flute and B-flute board protects contents through courier networks. For fragile or heavy items we recommend double-wall board or a custom insert, which we can design for you.
Can you print on the inside of the box?
Yes. Inside printing is one of the most popular options for e-commerce brands — a full-colour inside lid, a brand message or a pattern makes unboxing memorable and highly shareable on social media.
Are your mailer boxes recyclable?
Yes. Corrugated cardboard is among the most recycled packaging materials in the UK, and our mailers are fully kerbside-recyclable. FSC-certified and 100% recycled board grades are available on request.
How quickly can I get my mailer boxes?
Standard production is 5–7 working days from artwork approval, plus delivery anywhere in the UK. Express options are available for tight deadlines — just tell us your date when you request a quote.
Have a specific requirement or custom dieline?
Our UK packaging specialists can verify bottle clearances, create tailored structural CAD dielines, and supply physical plain samples.
Let’s make it yours
Ready to Upgrade Your Unboxing?
Get a free, no-obligation mailer box quote in under 24 hours. Tell us your product and quantity — we will recommend the right size, board and finish for your brand and postage budget.