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Custom Decorative Mailer Boxes

Custom decorative mailer boxes use corrugated paperboard and cardboard materials. You can customise them into any shape and size. They have foldable flaps. You can even incorporate your logo, brand colours, and some other designs to add an extra touch and make it more memorable. Personalised mailer boxes also carry Self-locking or tuck-end flaps. These boxes are great for products, gifts, or samples. They are also ideal for storage of small items.

Get Your Custom Quote

Share your box details and we will send your price.

1 Box Style
2 Material
3 Quantity
4 Contact

Choose Style

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.

Decorative Mailer Boxes Classification

Rigid boxes are strong but high-cost. Folded Carton boxes are very cost-effective, in addition to that they can also be used in various ways together. Mailer envelopes are lightweight and cost-effective, making them the appropriate choice for books but offer the least protection.

Kraft Boxes

These boxes have earthy tones and are biodegradable. Luxury boxes are the classiest, but they are also the most expensive. Custom-shaped boxes are crafted but are complicated and pricey.

Product protection, brand image, budget, shipping cost, and environmental impact should be some of the aspects that a business needs to consider when choosing a mailer box. This will assist you in selecting the optimal box for your business.

Material Choices

They offer us recyclable Kraft paper Boxes, which are wrapped from arrival paper plants. They have a natural, rustic design, often paired with minimalism.

However, Rigid Board Boxes are a very premium & very strong package that is best fit for high-end items. They enhance product perception and act as protective packaging during shipping for fragile items.

Design Configurations

They’re a straightforward, no-fuss option for everyday products and standard mailer boxes. They are an economical approach to simple deliveries. Formats include a Subscription Box, which caters to regular deliveries. This means packaging remains fairly consistent however, the unboxing is improved.

Specialised Packaging is customised for certain sectors and product requirements, such as wine and electronics. They are specially designed and sized to fit better.

Tip: Box printing with colours, foil, embossing, and window cutouts will affect the nature of the box. A magnetic closure is a stylish and secure way to hold jewelry.

Recent Trends:

Modern packaging design reflects trends such as:

  • Sustainable packaging
  • A minimalist design approach
  • Fine product presentation

However, by considering these factors, businesses can design custom mailer boxes.

How to choose decorative mailer boxes?

NO MOQs

Quantities that you must remember when ordering any custom mailer boxes. Usually, suppliers have MOQs because it is not economically effective for them to provide smaller quantities.

Bulk Orders

Of course, orders in bulk can help save dollars. You have to ensure that you do not order more than your warehouse can hold. It can lead to spoilage and huge losses. Moreover, you also have to think if you can sell all the products you do order from the wholesalers or not to avoid wastage again.

Volume-based pricing decreases the cost per unit of goods purchased. Moreover, comparing prices from various suppliers and channeling your requirements where the most funds can be saved can help, too.

Aspects should include:

  1. Box Design
  2. Custom sizes
  3. Product protection
  4. Shipping compatibility.

Another aspect of printing and availability of special features like:

  • full-colour printing
  • logo printing
  • graphic designing, etc.

They will help you to beautify these mailer boxes.

Prototyping

Prototyping includes creating digital mockups, iterative designs, and proof approvals from all stakeholders. Timeliness integrates turnaround time relevant factors like standard production windows, quick-turn production options, and combined component shipping timeline for on-time delivery.

Good ordering is the right proportion of how much you want, how much it costs, and how much quality. Understanding suppliers’ capabilities and corresponding them to your exact needs becomes crucial.

Packaging trends like:

  1. Sustainable packaging
  2. on-demand printing
  3. and digital packaging design tools

They can assist businesses optimise the ordering process and have essential guarantees that high-quality custom mailer boxes arrive.

Recommended for Strategic Ordering

Design Technology

Using some online design tools can help you with the design process. Interactive visualisation platforms and real-time 3D Box rendering provide a clearer image of what the end product will look like.

CAD Integration

AI-driven design suggestions can offer creative guidance and help optimise design selections. Digital prototyping allows you to visualise the box in the virtual form, allowing for an understanding of its limitations before moving to more expensive steps. CAD integration enables accurate measurements and structural analysis.

While predictive structural modeling makes certain the box can survive the stresses of shipping and handling. Virtual simulation of packaging minimises waste by assisting in optimising the packaging process.

Functional Performance

A box must be made up of a box that will be sufficient to protect the product. Durability testing (e.g., drop and vibration tests) to analyze its ability to survive shipping and handling stresses. Products to be shipped to different climates require environmental resistance such as moisture resistance and temperature tolerance.

Cost-Effective Strategies

Buying in bulk can trigger scale efficiency and cost savings over time. However, balancing bulk ordering with inventory is essential to avoid overstocking. This style helps reduce material and cost footprint and is considered a minimalist design approach.

You can achieve material efficiency by selecting suitable materials. Strategies such as recycling materials and reducing waste can save costs and benefit the environment.

Why Healey Packaging?

When ordering mailer boxes custom, the first thing is the number of boxes, dimensions, material, printing details, budget, and delivery time. Our company helps businesses develop effective and attractive packaging solutions with the right design, and cost-effective tools.

You can also order Corrugated Logo Shipping Boxes to get some extra discount. For orders and queries, contact us: 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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