CHRISTMAS SALE
Strong
Corrugated Cardboard
Fluted middle layer for strength and cushioning. Ideal for mailer boxes, shipper cartons, and any product that needs extra protection during delivery.
Mailer Packaging Boxes
Explore Our Premium Packaging Options
Mix and match materials, printing methods, inks, finishes, and add-ons to build packaging that feels completely on-brand. Start with the material, then move through print and finishing to see what fits your product best.
Eco
Natural Brown Kraft
Rustic, uncoated look that feels honest and sustainable. Great for bakery, subscription boxes, and earthy lifestyle brands that want a natural tone.
Premium
SBS / Bleach Card
Bright white, smooth surface for sharp printing and rich colors. Perfect for cosmetic cartons, medicine boxes, and premium retail packaging.
Luxury
Black Kraft / Black Card
Deep matte black stock that pairs beautifully with metallic foil. Best for luxury rigid boxes, apparel packaging, and special gift sets.
Flexible
Digital Print
Great for smaller quantities, seasonal packaging, or designs that change often. Fast setup with strong color output and no plate costs.
Classic
Offset Print
Industry standard for high-volume packaging. Ideal when you need consistent Pantone colors and the most economical cost per unit at scale.
Spot effects
Scodix Enhancement
Digital enhancement that adds raised UV, textures, and metallic-style effects to selected areas, creating a premium, touchable finish.
Gloss
UV Print
Cured with UV light for instant drying and strong color density. Works well when you need vibrant prints on coated boards.
Standard
CMYK Process Inks
Ideal for photography, gradients, and detailed artwork. Most packaging projects start here before adding special colors or finishes.
Branding
Pantone Spot Inks
Used when color accuracy is critical. Pantone inks lock in signature brand colors across different print runs and materials.
Bold
Screen Printing
Screen printing lays down a thicker layer of ink, creating vibrant solid colors and strong opacity. Best for bold logos, solid shapes, and designs that must pop even on darker materials.
Eco
Soy / Vegetable Inks
Lower-VOC options that support more sustainable packaging. Often paired with kraft stocks and minimalist designs.
Matte
Matte Lamination
Gives packaging a smooth, elegant feel with reduced shine. A favourite for luxury, cosmetic, and tech products.
Gloss
Gloss Lamination
Adds shine and extra ink protection. Works well for bold colors, retail shelves, and youth-focused brands.
Tactile
Soft-Touch Coating
Creates a velvety, rubberised feel that makes customers want to hold the box longer. Ideal for high-end unboxing experiences.
Highlight
Spot Gloss UV
High-gloss UV applied only to selected areas like logos or patterns, so they catch the light without making the whole box shiny.
Luxury
Foil Stamping
Metallic foil pressed into the board for instant shelf impact. Great for logos, borders, and badges on gift, cosmetic, and rigid boxes.
Raised
Embossing
Embossing lifts selected artwork from the surface, giving logos, patterns, and brand marks a premium 3D raised effect that customers can feel instantly.
Depth
Debossing
Debossing presses artwork into the board, forming an elegant recessed impression. Works beautifully for minimalist luxury packaging and fine-detail branding.
Windows
Die-Cut Windows
Custom window shapes let customers see the product before they buy. Can be left open or backed with clear PET where needed.
- Description
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
