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Mailer boxes are the workhorse of ecommerce shipping. Whether you need branded corrugated mailers, poly mailers for lightweight items, or padded envelopes for fragile goods, choosing the right supplier directly impacts your shipping costs and customer experience.
Shortlist view
Minimums and production times are provider-published starting points. Confirm the current terms for your product and destination.
| Provider | Good fit for | Published minimum | Published turnaround | Service area |
|---|---|---|---|---|
| noissue Source checked | Small to mid-sized ecommerce brands looking for custom sustainable packaging with very low MOQs — tissue paper from 250 units, mailers from 100 units. | Varies by product; selected custom mailers start at 100 units | Varies by product and customization; confirm the estimate shown for the selected item | Global |
| Arka Source checked | US-based ecommerce brands wanting custom packaging manufactured in America with self-service online ordering, Shopify integration, and sustainable options. | 1 branded mailer or shipper box | 7–10 business days after proof approval for selected custom boxes | United States |
| Brand in Color Source checked | Small businesses and startups wanting full-color custom shipping boxes and mailers in small order quantities with an online design tool. | 25 boxes for selected custom products | Company-published dispatch target of 3 business days for supported online products | United States |
| EcoEnclose Source checked | US ecommerce teams that want stock shipping supplies and custom recycled-content packaging from the same catalog, with documentation and sample access. | 100 branded shipping boxes; selected custom mailers start at 500 units; other formats vary | Stock products generally ship within 1–2 business days; custom production timing varies by product and begins after proof approval | United States |
| Grounded Packaging Source checked | Brands sourcing custom pouches, mailers, or rollstock that need material specification across recyclable, recycled-content, paper, and compostable structures. | Pouches from 6,000 units digitally printed or 10,000 rotogravure; mailer, bag, and rollstock minimums vary | Typically 6–10 weeks from artwork approval for reviewed pouch formats; confirm a project-specific schedule | Global |
| Hero Packaging Source checked | Australian ecommerce businesses buying small packs of shipping mailers or custom-branded mailers with product-specific compostability documentation. | Stock HEROPACK mailers from 25; custom non-padded compostable mailers from 500; custom padded mailers from 5,000 | Ready-to-ship products have a company-published same-day dispatch target; custom timing varies by product | Australia |
| TIPA Source checked | Brands and converters replacing conventional flexible film with product-specific certified compostable reels, laminates, bags, pouches, or mailers. | Reels from 500 kg per size or design; official regional pages list 5,000–25,000 units for selected premade or application formats | Typically 8–12 weeks for production after purchase order or final graphics, excluding shipping | Global |
| Roastar Source checked | Coffee, specialty-food, pet-treat, and small consumer brands ordering digitally printed bags, pouches, tins, tubes, labels, or mailers in short to medium runs. | Design Lab from 25 selected bags and 1 selected tin, mailer, or paper bag; fully custom bag minimums commonly start at 500–1,000 | Generally a couple of weeks after artwork approval and order placement; current product estimates are updated online | Global |
| Salazar Packaging Source checked | US ecommerce and subscription businesses sourcing custom corrugated shipping boxes, inserts, mailer envelopes, structural design, and shipment testing. | Typically 1,000 for selected custom or semi-custom corrugated boxes; some larger RSC formats may start at 500 | Approximately 2 weeks after approved artwork for selected first orders; confirm tooling, production, and delivery timing | United States |
| PAC by ProAmpac Source checked | Ecommerce and fulfillment teams sourcing stock or high-volume custom paper, poly, bubble, rigid, thermal, or automated protective-mailer programs. | 25,000 units per size for standard custom-printed mailers; stock or label-based options may support smaller requirements | Not publicly disclosed as a single standard — varies by product, customization, production location, approval, and delivery market | Global |
Custom tissue, stickers, mailers, tape, and related ecommerce packaging with product-specific minimums and compostable, recyclable, or reusable ranges.
US-manufactured custom packaging with online self-service ordering, FSC-certified and compostable options, and Shopify and ShipBob integrations.
US custom packaging provider for small businesses, offering full-color shipping boxes, mailers, and pizza boxes with online design and selected minimums from 25 boxes.
US supplier of stock and custom ecommerce packaging, including recycled shipping boxes, mailers, protective materials, tape, labels, and free sample options.
Global custom flexible-packaging provider offering pouches, rollstock, mailers, bags, recycled-content films, compostable structures, and online quote tools.
Australian ecommerce packaging supplier selling stock and custom mailers, boxes, tissue, labels, tape, and product-specific certified compostable shipping options.
Global supplier of compostable flexible films, laminates, reels, premade bags, pouches, mailers, and food or apparel packaging for brands and converters.
US digital packaging printer offering custom and stock bags, pouches, rollstock, tins, paper tubes, mailers, labels, stickers, online design, and samples.
US custom ecommerce packaging provider offering corrugated boxes, retail packaging, mailer envelopes, inserts, structural design, testing, and cost reviews.
Global protective-packaging manufacturer offering stock and custom paper, poly, bubble, rigid, and thermal mailers, printing, design support, and automation.
Planning utilities
Material options — E-flute corrugated for lightweight rigidity, B-flute for heavier items, and poly mailers for soft goods.
Print coverage — full-color exterior, interior printing, and edge-to-edge coverage for premium unboxing.
Size range — standard sizes for cost efficiency plus custom sizing to minimize DIM weight charges.
Tear strips and easy-open features that improve the unboxing experience and enable return-ready packaging.
Low MOQs for testing — ideally 100–250 units for initial orders.
Crush test ratings (ECT or Mullen) appropriate for your product's weight and shipping method.
Corrugated mailer boxes range from $0.80–$3.50 per unit depending on size, material, and print complexity. Plain kraft mailers start at $0.40–$0.80. Full-color printed mailers are $1.50–$3.50 at 500 units, dropping to $0.80–$1.80 at 2,500+ units. Poly mailers are the most affordable option at $0.08–$0.25 each for plain, $0.15–$0.50 for custom printed. Interior printing adds $0.15–$0.40 per unit. Tooling/plate fees for new designs typically run $100–$300.
Planning estimates are not live quotes. Material, dimensions, print coverage, finishes, freight, and order timing can materially change the final price.
What flute types do you offer, and which do you recommend for my product's weight?
Can I get full interior and exterior printing, and what's the cost difference?
Do you offer tear strips or self-seal closures?
What are your standard sizes, and what's the MOQ for custom dimensions?
Can I order a sample pack before committing to a production run?
How do you ship finished boxes to my warehouse — flat-packed or assembled?
E-flute is thinner (1.5mm) and lighter, ideal for small, lightweight products and detailed printing. B-flute (3mm) provides more cushioning and is better for heavier items or products that need more protection. Most ecommerce mailer boxes use E-flute for the balance of protection and print quality.
Corrugated mailers are best for rigid or fragile items, premium branding, and products that need structural protection. Poly mailers are best for soft goods (clothing, textiles), lightweight items, and budget-conscious shipping. Many brands use both — corrugated for hero products and poly for everyday shipments.
Choose the smallest box that safely fits your product with minimal void space. Use custom-sized boxes instead of one-size-fits-all. Consider adjustable-height mailer boxes that fold down to match product height. Every cubic inch of empty space costs money in DIM weight fees.
Yes. Many suppliers offer dual-adhesive-strip mailers — one strip for initial sealing and a second strip for returns. This eliminates the need for separate return packaging and creates a better customer experience.
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