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Corrugated Mailer Boxes

In terms of mailing, a corrugated sender box is very important. It protects your things while being transported, making sure they get there securely. A box that is tailor-made and has a personal element can change everything. For businesses like e-commerce and retail, the selection of corrugated boxes is intelligent. They help to solve problems related to shipping and at the same time increase brand awareness. The strong corrugated mailer boxes keep your products from harm. In the UK, companies are changing to personalised packaging.

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3 Quantity
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Why Choose Healey Packaging?

Premium printing, sustainable materials, fast turnaround, and reliable UK-wide service.

High Quality Printing

Sharp details, rich colours, premium print results.

No Minimum Order

Order from just 100 boxes — ideal for small runs.

Custom Sizes & Styles

Perfect tailored fit — at no extra design cost.

Eco-Friendly Materials

Recyclable, biodegradable, and FSC-certified.

Fast Turnaround

Quick production + reliable delivery times.

Free UK Shipping

Standard orders ship free across the UK.

Why Choose Custom Corrugated Mailer Boxes?

Corrugated mailer boxes are strong and sturdy. The layers in the different sections protect products from impacts and other external forces. In this design, the box itself is lightweight, which means it will be cheaper to ship. Corrugated mailers are available in multiple flute sizes, such as A, B, C, and E flutes. With each thickness and strength level per size.

The boxes are largely moisture resistant. The ability is useful for moisture-sensitive products. In addition, the vast majority of corrugated mailers are simple to construct. They usually come with basic tuck or lock flaps that allow for speedy, safe sealing. The features help businesses pack items faster and with minimal effort.

Various Types of Corrugated Mailer Boxes

Different industries and requirements have specific types of corrugated boxes that cater to them:

Corrugated single wall boxes:

Good for items with a lower weight. They provide general protection and are suitable for items which will not require a heavy duty packaging.

Double Walled Corrugated Boxes:

These boxes are made of two corrugated layers and offer additional protection. They are perfect for items that are heavier or fragile, it provides more padding and strength.

Die-Cut Corrugated Boxes:

These boxes are designed in a way that they take the shape to perfectly fit the respective items. They cradle products and disable movement within the box. Such type is suitable for such products that have unusual shape.

Litho-Printed Corrugated Boxes:

This printing technique helps to print classy and intricate designs on boxes. That’s a common option for high-end goods where presentation really counts.

Digital Printed Corrugated Boxes:

Flexible and cost effective for small runs. It enables businesses to quickly input logos, colours and styles.

Industry Applications

Different sectors require these corrugated mailer boxes with different specifications:

E-Commerce:

Used as shipping boxes for eCommerce products. They also offer branding opportunities, giving the customer a lasting unboxing experience.

Retail:

In retail space, these boxes increase attractiveness on store shelves. Not only do they keep items safe, but they also ensure a professional appearance to attract shoppers.

Food Packaging:

These corrugated mailers that come with a food-safe coating can be used for meal kits or items from your grocery store. These are just health-conscious, and food-friendly boxes.

Electronics:

Electronics are delicate and require careful handling. Devices and components that need better protection can be placed in corrugated boxes with extra padding.

Furniture:

For furniture, bigger reinforced corrugated boxes are ideal. This makes them just strong enough to be able to transport things safe and sound.

Customization Options

Customisation enables businesses to create boxes that reflect their brand. Take a look at a few things you can personalise:

Dimensions and Forms:

Custom-sizing aids in preventing the items inside the box from moving. Create an impression with custom shapes.

Perspectives on Printing:

Litho, digital, or colour printing used by businesses This assists with adding logos, messages, and branding to make the boxes feel extremely professional.

Some of the new items produced in materials need minimal effort and are eco-friendly and also water-resistant. They are long-lasting and attractive to eco-minded consumers.

Reinforced Corners & Edges:

Extra reinforcements help keep fragile items protected. It(is) a complementary security for valuable goods.

Affordable and Efficient Solutions

Corrugated mailer boxes are extremely light, and this saves shipping costs. When you use the right box size for products, you do not require any fillers and extra materials. Sturdier build means lower chances of broken stuff. This translates into lesser returns and swaps, thus, saving cash in the pocket in the long run.

They also increase efficiency in packing and shipping when custom size is chosen. This speeds up the packing of items, and thus management in general. Efficient packaging helps you cut down on time and ensures that the customers receive their items without any damage.

Eco-Friendly Corrugated Mailer Boxes

Recyclable corrugated mailer boxes reduces landfill waste and addresses the needs of consumers looking for sustainability. Biodegradable refers to those materials which try to confirm that any packaging will be around to harm the environment after it has served its purpose.

Eco-friendly production processes are an effective way for businesses to minimise their environmental footprint. When brands adopt sustainable packaging solutions they prove themselves responsible.

Retail Your Success with Custom Corrugated Mailer Boxes

Find out how to measure, the most important things you need to know to assess if your packaging is working –
A reliable delivery indicates that your boxes are doing their job perfectly ach time. Quick Delivery helps Client Satisfaction.

Positive comments on the quality of your packaging speak highly of your brand, as relates customer feedback. Listen to customer feedback to never stop improving.

Returns need to be reduced to maintain a good Return on Investment (ROI); where customers are as satisfied as ever! This demonstrates that it is worth to invest into quality boxes.

Choosing the Right Supplier

Choose a trustworthy vendor. There are several suppliers based in the UK that offer effective and tailor-made packaging ideal for both large and small businesses like Healey Packaging. A high-quality supplier provides good materials, quick lead times, and customization flexibility.

You should consider price, durability and reliability when it comes to delivery. By sourcing high quality boxes from an experienced supplier such as Healey Packaging you can ensure a much smoother operation for your business and a consistent delivery of quality goods to your customers.

UK-Based Custom Corrugated Mailer Boxes Company

Custom printable corrugated mailer box packaging- Always a wise decision for UK-Based businesses. These options give long-lasting, customizable, and recyclable alternatives that create assistance in product coverage and branding. Its lightweight construction keeps shipping costs down, and its ability to be custom printed allows brands to differentiate.

Contact Healey Packaging today to learn more about the right types of corrugated boxes for your business. We are waiting for your email help@healeypackaging.co.uk.

Dimension (L + W + H) All Custom Sizes & Shapes
Quantities No Minimum Order Required
Paper Stock 210gsm, 250gsm, 280gsm, 300gsm, 350gsm, 420gsm, 460gsm, 500gsm,
Bleach Card (SBS), Eco-Friendly Kraft, E-flute Corrugated, Bux Board, etc.
Printing No Printing, CMYK, CMYK + 1 PMS color, CMYK + 2 PMS colors
Finishing Gloss Lamination, Matte Lamination, Gloss AQ, Gloss UV, Matte UV,
Spot UV, Embossing, Foiling
Included Options Die Cutting, Gluing, Scoring, Perforation
Additional Options Eco-Friendly, Recycled Boxes, Biodegradable
Proof Flat View, 3D Mock-up, Physical Sampling (On request)
Turnaround 7 – 10 Business Days, RUSH
Shipping FLAT

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.

Strong Corrugated cardboard sheets

Corrugated Cardboard

Shipping • E-commerce • Heavy items

Fluted middle layer for strength and cushioning. Ideal for mailer boxes, shipper cartons, and any product that needs extra protection during delivery.

DurableProtective
Eco Natural brown kraft board

Natural Brown Kraft

Eco brands • Food • Lifestyle

Rustic, uncoated look that feels honest and sustainable. Great for bakery, subscription boxes, and earthy lifestyle brands that want a natural tone.

RecyclableOrganic feel
Premium White SBS bleach card

SBS / Bleach Card

Beauty • Pharma • Retail

Bright white, smooth surface for sharp printing and rich colors. Perfect for cosmetic cartons, medicine boxes, and premium retail packaging.

High print qualityClean white
Luxury Black kraft packaging board

Black Kraft / Black Card

Luxury • Gifts • Apparel

Deep matte black stock that pairs beautifully with metallic foil. Best for luxury rigid boxes, apparel packaging, and special gift sets.

Premium lookFoil-ready
Flexible Digital printing press

Digital Print

Short runs • Variable data

Great for smaller quantities, seasonal packaging, or designs that change often. Fast setup with strong color output and no plate costs.

Low MOQFast
Classic Offset printing rollers

Offset Print

Larger runs • Brand colors

Industry standard for high-volume packaging. Ideal when you need consistent Pantone colors and the most economical cost per unit at scale.

Sharp detailCost-effective
Spot effects Scodix enhancement print

Scodix Enhancement

Tactile • Raised effects

Digital enhancement that adds raised UV, textures, and metallic-style effects to selected areas, creating a premium, touchable finish.

3D feelHighlight details
Gloss UV print on packaging

UV Print

High gloss • Rich color

Cured with UV light for instant drying and strong color density. Works well when you need vibrant prints on coated boards.

ShinyDurable
Standard CMYK ink cans

CMYK Process Inks

Full color • Gradients

Ideal for photography, gradients, and detailed artwork. Most packaging projects start here before adding special colors or finishes.

Full colorVersatile
Branding Pantone ink swatches

Pantone Spot Inks

Exact brand tones

Used when color accuracy is critical. Pantone inks lock in signature brand colors across different print runs and materials.

ConsistentOn-brand
Bold Screen printing ink layers

Screen Printing

Thick ink • Bold coverage

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.

OpaqueVibrant
Eco Eco friendly vegetable inks

Soy / Vegetable Inks

Eco packaging

Lower-VOC options that support more sustainable packaging. Often paired with kraft stocks and minimalist designs.

Low VOCEco-minded
Matte Matte laminated box

Matte Lamination

Soft touch • Low glare

Gives packaging a smooth, elegant feel with reduced shine. A favourite for luxury, cosmetic, and tech products.

PremiumModern
Gloss Gloss laminated packaging

Gloss Lamination

Shiny • Eye-catching

Adds shine and extra ink protection. Works well for bold colors, retail shelves, and youth-focused brands.

ShinyScuff-resistant
Tactile Soft touch coated box

Soft-Touch Coating

Luxury feel

Creates a velvety, rubberised feel that makes customers want to hold the box longer. Ideal for high-end unboxing experiences.

VelvetyPremium
Highlight Spot UV gloss on box

Spot Gloss UV

Logo & details

High-gloss UV applied only to selected areas like logos or patterns, so they catch the light without making the whole box shiny.

ContrastLogo focus
Luxury Gold foil stamping on packaging

Foil Stamping

Gold • Silver • Custom

Metallic foil pressed into the board for instant shelf impact. Great for logos, borders, and badges on gift, cosmetic, and rigid boxes.

MetallicPremium detail
Raised Embossed packaging surface

Embossing

Raised detail

Embossing lifts selected artwork from the surface, giving logos, patterns, and brand marks a premium 3D raised effect that customers can feel instantly.

3D liftPremium texture
Depth Debossed packaging surface

Debossing

Pressed detail

Debossing presses artwork into the board, forming an elegant recessed impression. Works beautifully for minimalist luxury packaging and fine-detail branding.

IndentedLuxury
Windows Box with die-cut window

Die-Cut Windows

Show the product

Custom window shapes let customers see the product before they buy. Can be left open or backed with clear PET where needed.

RetailProduct focus

Loved by Real Customers

Liz Wheelhouse
★★★★★

“We reached out to Healey Packaging to help us create bespoke shaped boxes… the final product looked amazing and was very well received.”

November 18, 2025
Ash
★★★★★

“Very happy with the service and print quality. Patient with revisions and great communication. A very positive experience.”

September 18, 2025
Vanessa Scott
★★★★★

“The printing quality was excellent and Alex was incredibly helpful. I’ll definitely use Healey Packaging again.”

June 6, 2025
Adrian Tang
★★★★★

“Excellent service, very good quality and sharp printing. Highly satisfied with the results.”

May 7, 2025
G. Mitev
★★★★★

“Our custom boxes arrived exactly how we imagined. Great quality and friendly support from start to finish.”

April 21, 2025
Scott Anthony
★★★★★

“Really great branded hat boxes. Perfectly printed and excellent service. Will definitely return.”

April 14, 2025
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