Custom Black Mailer Boxes

Printed Inside, Printed Outside

The outside is usually black with a logo on the lid. White ink gives a bold graphic look; gold, silver or rose gold foil gives a premium finish; spot UV on matt black creates a subtle glossy logo. Some brands repeat a small logo pattern across the whole lid or add a website along one side.

The inside is where many brands get creative. Printing the inside of the lid with a message, a pattern or a bright brand colour means the first thing the customer sees after opening is another layer of your brand. A black exterior with a pink, gold or white interior is a popular combination that looks striking in photos.

Double-sided printing adds cost, so decide whether you want a full interior print or a single message on the inside of the lid.

Choosing the Right Mailer Size

Measure your products as they will be packed, including any tissue, inner boxes or inserts, and size the mailer to the internal dimensions. A box that fits closely looks better when opened and needs less void fill. A box that is too large lets products slide around and can push you into a higher postage band.

Most brands manage with two or three sizes. A small mailer for jewellery and beauty, a medium mailer for a folded tee or a couple of products, and a larger one for hoodies or bundles. Using the same design across all sizes keeps the brand consistent and simplifies artwork.

If you post through letterboxes, a slim mailer under the size limit for large letters can reduce postage costs significantly for flat items.

Think about stock levels for each size. The medium mailer is usually the workhorse and runs out first, so order more of it and fewer of the large size, which tends to be used only for bundles and sale periods.

Board Choices for Posting

Most black mailers are made from E flute corrugated board, which is about 1.5 mm thick, prints sharply and protects clothing and cosmetics well in the post. B flute, about 3 mm thick, suits heavier items such as candles or glass jars. The outer liner is black, either dyed or printed, while the inside is white or brown.

Matt black is the most popular finish, while a soft-touch laminate gives the lid a suede-like hand. Note that scuffs from courier networks show more on gloss finishes, so matt or soft-touch usually look better on arrival.

If your products are fragile, combine E flute with a card insert rather than jumping straight to thicker board. The insert holds items in place, and the box stays slim, light and sharp to print on.

Packing an Order That Gets Shared

Fold the mailer, line it with tissue, place the product in the centre and fold the tissue over. Seal the tissue with a branded sticker. Add a thank-you card on top, close the lid and tuck it in. If you want a tamper-evident seal, add a sticker across the front tuck or use a mailer with a tear strip.

Place the shipping label on the base or underside of the box, or on a plain panel, so it does not cover your logo. A small sticker with your social handle on the inside of the lid encourages customers to share their unboxing.

Keep a packing station laid out in the order you work: flat mailers, tissue, stickers, cards, then a space for finished boxes. A tidy station makes every order look the same, and consistency is what customers notice when they order a second time.

For subscription boxes, vary the card or the tissue colour each month while keeping the black mailer the same. Customers get something new to look forward to without you reprinting the box.

Ordering Your Black Mailers

Send the internal dimensions, board choice, print and finishes, and quantity, and we will reply by email with a custom quote within one working day. Minimums are low and quoted per job, so a growing brand can start with one size and add others as it expands.

A free design proof shows the box flat, inside and out. Once you give the go-ahead, the mailers are made over 4 to 7 working days and then sent free and tracked to UK mainland addresses, landing in 2 to 3 working days as flat bundles. If any arrive damaged or misprinted, report it within 10 days for a reprint or refund.