Mailer Packaging Boxes

Custom Mailer Packaging Boxes for Shipping That Sells

When your product travels, your packaging speaks for your brand before the customer ever opens it. That’s why our custom mailer boxes are built for more than just protection — they’re made to surprise, impress, and retain.

Whether you’re sending out subscription kits, ecommerce orders, influencer PR boxes or startup launches, Healey Packaging designs mailer boxes that hold up in transit and look good doing it. With tailored sizes, eco-conscious materials, and full-colour printing inside and out, you’ll get packaging that works hard from doorstep to unboxing.

Built for the Journey — and the Reveal

From strength to style, mailer boxes need to do more than just survive shipping. We engineer packaging that arrives intact and leaves a lasting impression.

Popular Use Cases:

• DTC Ecommerce Brands (beauty, apparel, stationery, lifestyle goods)
• Subscription Boxes (monthly skincare, snacks, fitness kits, etc.)
• Product Launch PR Mailers
• Retail Ready Packaging with Shipping Protection

Our designs prioritise durability and delight, giving you a secure structure plus space for branding and messaging.

Box Styles That Work for You

All of our mailer boxes are fully customisable. A few client favourites include:

Roll End Tuck Front (RETF)

Classic ecommerce style. Strong, reusable, and great for branded unboxing.

Roll End With Dust Flaps

Offers added protection during shipping. Best for heavier products or multi-item kits.

Custom-Size Mailers

Unique sizing available for long, flat, round, or oddly-shaped products. No standard templates here — just what fits your item.

Optional add-ons:

• Internal inserts for product separation
• Pull tabs or peel-and-seal strips
• Inside print for surprise messaging or instructions

Eco-Friendly Mailer Packaging Options

Sustainability is no longer a “nice to have” — it’s what customers expect. Our mailer boxes come in:

• 100% recyclable kraft or white corrugated board
• FSC-certified materials upon request
• Soy-based or water-based inks
• Plastic-free coating options

If you’re building a greener brand, we’ll make sure the packaging follows suit—right down to the material choice and whether you want a recycling icon tucked on the bottom flap.

Branded to Tell Your Story

Custom doesn’t just mean size — it means experience. With our range of finishes and print capabilities, your mailer box becomes a tactile expression of your brand.

• Exterior & interior printing
• Custom colour matching (Pantone/CMYK)
• Foil stamping and embossing
• Spot UV for logo highlights
• Soft-touch or matte coatings for upscale feel

We’ll help you find the right combination — bold or minimal, premium or playful — to leave your customer saying “wow” before they’ve even touched the product.

Small Runs or Large Volumes — We Scale With You

Whether you’re a subscription startup testing 100 boxes or a national brand shipping 10,000, we offer flexibility built around how you operate:

• MOQ starts at 100 boxes
• 7–10 business day turnaround from final proof approval
• Flexible design splitting across SKUs or sizes
• Bulk discounts for repeat or high-volume orders

We’ve supported growing brands from first launch to full warehouse scale-up — and we’re happy to do the same for yours.

Free Dielines, Artwork Support & Print Proofing

No in-house designer? No problem. We offer:

• Free dieline templates matched to your size
• Guidance on bleed, safety, fold zones
• Proofs with layout review before print
• 3D mockups upon request for presentations or marketing use

Your boxes won’t just look good — they’ll print right the first time.

Frequently Asked Questions – Mailer Edition

Can I print inside the box too?

Yes! Interior printing is a popular choice for messaging, branding, or tutorials. Adds big impact without huge cost.

Are your mailer boxes recyclable?

Absolutely. Our kraft and white mailers are 100% recyclable and can be made from post-consumer content too.

Can you help if I don’t know my box size?

Of course. Send us the product dimensions or photos and we’ll recommend the right internal clearance and box style.

Do mailer boxes come assembled?

No — they ship flat to save space. They’re quick to fold and seal, no tape required unless requested.

What’s your fastest turnaround?

Most projects are complete in 7–10 working days. We also accommodate rush jobs — just give us a heads-up.

Why Choose Healey Packaging for Your Mailer Boxes?

Because we combine old-school customer care with modern production tools. You’ll never be left guessing about box styles, material options, or design setup. We guide you through the whole process — whether you’re posting handmade candles or building the next top 100 DTC brand.

Our packaging team is UK-based, hands-on, and available to walk you through:

• Tailored to your brand / Branding ideas – fully personalised mailer boxes with logo and design

• High-quality materials – rigid, corrugated, and kraft cardboard options
• Free design support – our in-house experts help bring your vision to life
• UK-based production  – faster lead times and local customer service
• E-commerce integration (mailer + retail combo boxes)
• Eco-conscious options – we offer recyclable and eco friendly boxes as standard

From printed to luxury mailer boxes for premium brands or start-ups, we deliver solutions that balance performance, design, and sustainability