Format 04 · Mailer
E-commerce mailer
Corrugated boxes designed for courier handling and a clear opening experience. Exterior and interior print can carry the brand through delivery and unboxing.
A strong fit when
- The product ships direct to a customer with no outer carton
- Unboxing is filmed, photographed or posted
- You need something that survives a regional courier network
- Returns come back in the same box
Consider another format when
- The item is small and light enough for a padded envelope
- The box goes into retail, where corrugated flute reads as transit packaging
How it is built
The construction decisions that shape the result.
- 01Flute
- The corrugated wave between the liners. E-flute has a finer profile and prints well; B-flute is stronger but can show more of its rib pattern through the print.
- 02Roll-end tuck
- A common mailer construction that folds up without glue, locks with side wings and opens without a knife.
- 03Inside print
- Requires a second print pass and creates the surface seen during opening. Whether to print inside, outside or both depends on the delivery and unboxing priorities.
- 04Tear strip
- A perforated opening line that makes the pack easier to open. Once used, the same strip cannot reseal the box for a return.
Stocks we run
- E-flute corrugated, kraft or white liner
- B-flute for heavier contents
- Recycled-content liners
Finishes available
- Flexo or litho-laminated print
- Full-coverage interior colour
- Die-cut handles and tear strips
- Water-based coatings
Quantities and lead time
Both depend on structure, stock and finish, and quoting them without a live brief would be misleading. Share the job and we will price the specification against your date.
Start a mailer briefServices that cover it
E-commerce mailer questions
Useful before we begin.
01Litho-laminated or direct print?+
Direct flexographic printing applies ink to the liner and is often efficient for one or two solid colours. Litho lamination prints a separate sheet and mounts it to the corrugated, supporting photography, gradients and finer type. Artwork, quantity and required reproduction quality determine the better option.
02Will a printed mailer survive Saudi courier handling?+
The flute, liner weight, structure and product fit carry most of the transit load; print alone does not determine performance. The specification should be assessed against the product weight, fragility, packing method and intended delivery network.
Specify the project
Let us shape the right mailer around the job.
Share the contents, dimensions, quantity, finish direction and delivery date. We will identify the decisions that need a sample, proof or structural check.