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Custom Mailer Boxes Wholesale

Mailer boxes are available in many types, such as custom mailer boxes, shipping boxes, pillow boxes, postal boxes, and rigid boxes. These can range from small to large sizes and dimensions. We use advanced printing techniques like digital printing and flexographic printing for bright, clear designs. Finishing options include matte, glossy, and spot UV coatings for added style. Other features like locking tabs and adhesive strips, keep the boxes securely closed during transit. Custom mailer boxes are Ideal for e-commerce, gifts, subscription services, and promotional purposes.

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1 Box Style
2 Material
3 Quantity
4 Contact

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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.

Best Custom Mailer Boxes

Do you know? Online shopping hit $5.7 trillion in 2022. It is estimated that it will reach $7.4 trillion by 2025. This growth proves the demand for effective packaging solutions. Mailer boxes are essential for shipping products. They protect precious products during shipping. These custom mailer boxes also enhance branding.

In UK, our company offers different types of mailer boxes. Our best mailer boxes are:

  • Custom envelope boxes
  • Custom printed mailer boxes
  • Postal Boxes
  • Branded Mailer Boxes
  • Personalised Postal Boxes
  • Durable Custom Mailer Boxes

Types of Mailer Boxes

Cardboard Mailer Boxes

Cardboard mailer boxes are lightweight and strong. They are a popular choice for many businesses. They protect items during shipping.

Examples:

  • Standard Mailer Boxes: These boxes are commonly used for e-commerce products, like apparel and accessories.

Custom Mailer Boxes

Custom mailer boxes are tailored to your brand. You can print logos and designs at your custom mailer boxes.

Applications:

  • Gift Boxes: Brands can send personalised gifts using distinctive designs to surprise recipients. A study by Dotcom Distribution found that 60% of consumers prefer to receive gifts in branded packaging.

Rigid Boxes

Rigid boxes offer extra sturdiness and a luxurious feel. They provide excellent protection for premium items. They ensure safety and style.

Examples:

  • Luxury Product Packaging: Brands like Chanel and Dior use these boxes to offer quality in their products.
  • Retail Display Boxes: These are attractive packaging for stores. These boxes improve product appearance.

Shipping Boxes

Shipping boxes are versatile and designed for larger items. They are strong and offer great safety for products.

Applications:

  • Online Retail: Companies like Amazon and Walmart use shipping boxes for their products to improve delivery tasks.
  • Bulk Shipping: These boxes are Ideal for shipping multiple items for wholesalers or manufacturers.

Postal Boxes

Postal boxes are lightweight and easy to assemble. They have self-sealing closures for quick packing.

Examples:

  • Flat Postal Boxes: Flat postal boxes are perfect for shipping documents. These boxes are commonly used byprinting services.
  • Crash Lock Boxes: These boxes are designed for easy assembly. They are ideal for quick shipping needs.

Packaging Boxes

Packaging boxes can be used for various purposes, including food and retail.

Applications:

  • Crafts and Hobbies: These boxes are used by small businesses for packaging art supplies, like Etsy sellers.
  • Retail: Packaging for small gadgets and accessories.

Dimensions and Sizes of Printed Mailer Boxes

Mailer boxes come in various sizes. Here are some standard dimensions:

  • Small: 15x12x5 cm, suitable for small products like cosmetics or jewellery.
  • Medium: 20x14x8 cm, ideal for books or tech accessories.
  • Large: 35x25x10 cm, used for clothing or larger items.
  • Extra Large: 50x50x15 cm, perfect for bulk shipping or larger gifts.

Free Design Support for Cardboard Mailers

Customisation enhances the unboxing experience and brand visibility. At Healey Packaging, we offer several options:

  • Brand Colours and Logos: You can use your brand’s colours and logo for your product. It increases your brand recognition.
  • Interior Printing: Surprise customers with messages or graphics inside the box. It will create a memorable experience.
  • Custom Inserts: Add foam or cardboard inserts to secure precious items. These customs inserts ensure safety.
  • Unique Shapes: You can design boxes in various shapes to boost your sales.
  • Tapes and Stickers: Use branded tape or stickers to seal boxes. It will improve branding and customer experience.

Printing Techniques for Mailer Packaging

Printing on mailer boxes enhances branding and aesthetic appeal. Several techniques can be used:
Digital Printing: Digital printing adds vibrant colours and complex designs. This technique is perfect for small orders. It is also cost-effective for short runs.

  • Flexographic Printing: This technique is suitable for large orders with simple designs. It is ideal for businesses looking for bulk printing.
  • Lithographic Printing: This type of printing produces high-quality images. It is suitable for smaller batches and premium packaging.
  • Screen Printing: Screen printing is best for bold, solid colours and larger quantities. It is often used for logos and striking designs.

Creative Ideas for Postal Boxes

  • Augmented Reality (AR): Many brands use augmented reality via product package. When the customer points their device at the box, it reads the label and then displays information about the product on top. And it also will boost the level of engagement.
  • Smart Packaging (QR codes and NFC tags): Customers scanned these codes for product information. According to Research and Markets, the smart packaging market is expected to reach approximately $50 Billion by 2027.

Premium Finishing for Custom Die Cut Mailers

The following finishing techniques are used for custom mailer boxes:

  • Gloss or Matte Finish: Both these coatings are done to increase the appearance and standard of your products. Gloss is shiny, and matte is smooth.
  • Embossing and Debossing: Produces a 3-D effect on logos and designs making them more attractive.
  • Foil Stamping: For a glossy cover for luxury brands.
  • Custom Die-Cutting: Custom Die-Cutting improves odd shapes.

Custom Postal Boxes Materials

The choice of materials is crucial to guarantee high-quality product:

  • Corrugated Cardboard: This is the most common material for mailer boxes. It has strong protective properties. It is fully recyclable.
  • Kraft Paper: Kraft paper is ecologically friendly and decomposes easily.
  • Recycled Materials: Businesses can use recycled materials to help reduce their carbon footprint.
  • Biodegradable Options: These decompose faster in the environment. It causes less pollution.

List of Popular Mailer Box Examples

  • Custom Printed Mailer Boxes: Personalised boxes used by brands like Loot Crate, enhancing the customer experience.
  • Kraft Mailer Boxes: Eco-friendly options that many small businesses prefer for sustainable practices.
  • Mailer Boxes with Locking Tabs: Secure closure systems used by cosmetics brands for safe transport.
  • Wine Bottle Carriers: Used by wineries and gift shops to transport bottles safely, often featuring custom designs.

Mailer boxes are crucial for shipping and branding. At Healey Packaging, we provide a wide range of mailer boxes suitable for every business need. Companies can improve customer experiences and boost sales by using Custom mailer boxes.

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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