Postal Boxes

Custom Postal Boxes for Your Packing Workflow

A one-piece hinged mailer keeps the lid attached to the base and folds into shape when needed. Suitable die-cut formats arrive flat-packed, taking up less storage space before use. Check the folding sequence against your packing process, especially when adding an insert.

Locking tabs hold the lid in position, but the dispatch seal needs separate consideration. A suitable self-seal design uses an integrated adhesive strip; other formats may need tape across the closing join. A tear strip gives the recipient an opening point but cannot reseal the box.

For customer returns, discuss a construction with a second adhesive strip and check that the box remains usable after opening. Larger orders may suit a conventional shipping carton; our ecommerce dispatch formats cover other packing arrangements.

Keep the Contents in Place During Dispatch

Loose products can strike each other or move against the box walls. Fitted paperboard or corrugated inserts can locate individual items, while dividers separate products within a set. Fragile contents may also need cushioning: keeping bottles apart does not, by itself, establish impact protection.

For gift orders, decide what the recipient should see. One printed corrugated pack may serve as both the postal box and presentation pack. A separate outer carton can shield a gift box from carrier labels and direct handling.

Match the Finished Parcel to Your Postal Service

Measure everything going inside, including retail packaging, inserts and cushioning. Specify the usable internal length × width × depth, allowing clearance for packing and closure. Then establish the filled, closed parcel’s external dimensions and total weight, including any additional wrapping.

For an A4 item, allow for its full thickness, any folder or retail wrap, and protection around it. Small, large, flat and long postal boxes describe formats rather than fixed dimensions.

For reference, Royal Mail’s 1st Class service lists these limits, checked on 30 October 2026:

These are carrier limits, not the load capacity of a particular box. Check your actual service or contract before ordering.

Avoid sizing the pack exactly to a service limit: board thickness, packing tolerances and bulging can increase its finished dimensions. If delivery through a door opening matters, consider slim letterbox packaging separately. Meeting a carrier category does not guarantee a fit through every letterbox.

Choose Board Around Weight and Handling

Corrugated postal boxes have flat liners and a fluted layer. Select the board around packed weight, box dimensions and handling conditions. Single-wall board may suit lighter orders; double-wall can be considered where the filled pack needs more support.

Brown kraft-faced and white-faced options provide different printing surfaces. Neither colour establishes board strength or recycled content. Our guide to packaging constructions explains the difference between corrugated outers and retail or presentation boards.

For recycling advice, assess the complete pack, including coatings, adhesive and added parts. Brown board alone does not establish how the finished packaging can be recycled.

Plan Printing Around Labels and Opening

Printed postal boxes can carry a simple logo outside, full-colour artwork or a message beneath the lid. Brown liners affect printed colours, so review artwork against the proposed surface.

The printing route depends on the stock, design and quantity. Options may include direct printing or a printed sheet laminated to corrugated board.

Leave a flat area for address labels and carrier barcodes, away from folds and tear paths. A matt or gloss finish changes the surface appearance; foil and spot UV may suit selected gift designs where compatible. Check label adhesion and consider how the finish affects recycling.

Confirm the Specification Before Ordering

Send packed product measurements, weight, delivery route and quantity with your enquiry. Include your preferred closure and any insert requirements. We can help with board selection, structural design and a custom dieline.

Where a physical sample is needed, confirm its availability and use it to check fit, assembly and closure. Agree any required transit testing separately.

Upload reference images through the quote form. Email print-ready PDF, AI or PSD artwork to sales@healeypackaging.co.uk with your enquiry reference.

Production takes 7–10 working days after artwork approval, with transit additional. Delivery of your packaging order is free across the UK and USA, including all US states. Healey covers applicable import duties and taxes. Postage for sending your own packed products is separate.

Keep the approved dimensions, board, artwork, closure and insert details for repeat orders. Review them whenever the contents change.