Custom Tuck Top Mailer Boxes

Board Grades

E-flute corrugated is the usual choice. It is about 1.5 mm thick, prints sharply and keeps the box light, which matters for postage. B-flute, around 3 mm, is stiffer and better for heavier items or boxes that will be stacked under other parcels. For very heavy or fragile goods, an E and B double-wall combination gives extra strength.

White-lined board gives the brightest print and a clean look, while kraft board gives a natural appearance and hides scuffs from transit. Many brands choose kraft outside and white inside, printing a colourful pattern or message inside the lid while keeping the outside simple. The flute profiles are described in our board and card types guide with the weights each one suits.

Printing Inside and Out

The outside of a mailer travels through the postal system, so it does not need to carry everything. A clear logo on the lid and a return address on one side are often enough, with space left for shipping labels. Some brands keep the outside plain for privacy, especially for gifts or personal products.

The inside is where many brands focus their design. A printed inside lid with a thank you message, a pattern in brand colours or a short note about the product makes the moment of opening memorable. Because the inside is protected from scuffs, it can carry fine detail and bright colours.

Full colour printing suits detailed designs, while one or two spot colours on kraft is economical for larger runs.

Do not forget the side walls. When boxes are stacked in a delivery van or on a doorstep, the sides are often the most visible part, so a small logo on each side keeps the brand visible.

Sizing for Postage

Postal rates in the UK depend on size and weight bands, so a few millimetres can make a real difference. Measure your product with any tissue, inserts or protective wrap, add a small margin and check the outside dimensions of the box, which are larger than the inside because of the board thickness.

Shallow mailers that fit large letter size bands can save significantly on postage for slim items such as clothing, cards and cosmetics. Deeper boxes suit candles, mugs and gift sets. We can suggest a size range that covers your products with the fewest box sizes.

Remember that a box which is too large is not just a postage problem. Empty space lets products move and invites crushing, so the snuggest box that still allows room for wrapping is usually the safest choice as well as the cheapest to send.

Inserts and Extras

Tuck top mailers pair well with inserts. Card or corrugated inserts with cut-outs hold bottles, jars and electronics in place. Foam suits fragile items. For subscription boxes with changing contents, tissue paper, crinkle fill or a simple divider is usually enough.

Tear strips make opening easier and give a tamper-evident seal. Peel-and-seal adhesive strips on the tuck flap allow the box to be sealed without tape, and a second strip can be added for returns. Air holes are available for plants and other living goods.

Business cards, thank you notes and discount codes can sit on top of the product, under the lid, where they are the first thing the customer sees. Some brands print the message directly on the inside lid instead, which saves inserting a card in every box.

Settle the Postal Band Before the Dieline Is Drawn

The cheapest tuck top mailer is the one that drops into the lowest postal band your product allows, so begin with the courier's size table rather than the product. Check the large letter limit for slim goods and the small parcel limit for everything else, then measure your product at its thickest point including any tissue or insert and see which band it can reach with 5 mm of clearance. Ask for the box at that size. If the item is fragile, decide now whether an insert is needed, because an insert adds depth and can push the box up a band. Slim items that cannot reach large letter often travel in the flatter side-loading mailers that open on the short edge.

Prepare a logo for the lid and a second file for the inside, then email both with the internal size, board, quantity and any tear strip. A custom quote follows within one working day and a free design proof after that. Mailers are made in 4 to 7 working days once approved and delivered flat, free and tracked, to UK mainland addresses in 2 to 3 days. Boxes that arrive misprinted or crushed are reprinted or refunded when reported within 10 days.