The Ultimate Guides
of Custom Packaging Boxes

Types of Mailer Boxes

Types of Mailer Boxes

In today’s technologically evolving time, the demand for efficient and secure packaging solutions has never been higher. Mailer boxes have emerged as a popular choice for businesses and individuals alike, providing a versatile and customizable option for shipping various items. In this comprehensive article, we will explore the various types of mailer boxes available in the market, discovering their unique features, advantages, and best use cases.

Corrugated Mailers

Corrugated Mailers are among the most widely used types of mailer boxes. Comprising three layers of paper, with a corrugated inner layer sandwiched between two flat layers, these custom shipping boxes offer exceptional strength and durability. The corrugated structure provides excellent cushioning, making them suitable for shipping fragile items. Additionally, corrugated mailers are eco-friendly, as they are often made from recycled materials and can be recycled after use.

Padded Mailers

For added protection during shipping, padded mailers are an excellent choice. These Mailer Boxes feature a layer of protective padding, typically made of bubble wrap or foam, encased within a durable outer layer. Padded mailers are ideal for shipping delicate and valuable items such as electronics, jewelry, or small accessories. The padding absorbs shocks and impacts, reducing the risk of damage during transit.

Bubble Mailers

Bubble mailers, also known as bubble envelopes, are characterized by an outer layer of tough plastic or paper combined with an inner layer of bubble wrap. The bubble wrap provides an extra layer of cushioning, making these mailers suitable for shipping items that require protection against impacts and vibrations. Bubble mailers are lightweight, making them a cost-effective and efficient solution for a variety of shipping needs.

Rigid Boxes

Rigid Boxes, often referred to as rigid mailers, are known for their robust and unyielding construction. These mailers are designed to provide maximum protection for high-value and fragile items. Rigid boxes
are typically made from thick and sturdy materials such as chipboard or heavy-duty cardboard. They are an excellent choice for shipping items like electronics, glassware, or collectibles that demand extra care and protection.

Corrugated Mailers

When it comes to ensuring the safety of your shipments, corrugated mailer boxes stand tall as the go-to choice for many businesses. These robust packaging solutions are crafted with a unique construction, featuring a corrugated layer that adds strength and durability. In this section, we delve into the world of corrugated mailers, exploring their design, benefits, and why they are the trusted guardians of your precious cargo.

Cardboard Mailer Boxes

Cardboard Mailer Boxes have long been a staple in the world of packaging, offering versatility and reliability. From protecting delicate items to presenting a professional image, cardboard mailers have proven their worth in various industries. In this segment, we explore the myriad uses of cardboard mailer boxes, their customization options, and the reasons why they continue to be a preferred choice for businesses seeking both functionality and aesthetic appeal in their packaging solutions.

Collapsible Boxes

Collapsible boxes are a versatile and space-efficient option for shipping a variety of items. These mailers are designed to be easily assembled and disassembled, allowing for convenient storage when not in use. Collapsible Rigid Boxes are often used for e-commerce packaging, where businesses need a solution that optimizes storage space and reduces shipping costs. The ability to collapse the box when empty is a practical feature that appeals to both businesses and consumers.

Folding Boxes

Folding Boxes, also known as foldable cartons, are a popular choice for packaging products with a focus on branding and presentation. These mailers are made from paperboard and can be easily folded into shape. Cosmetic Foldable Boxes offer a customizable surface, making them ideal for printing logos, product information, and promotional messages. This type of mailer is commonly used in Retail Packaging for items like cosmetics, clothing, and consumer goods.

Paperboard Mailers

Paperboard mailers are an eco-friendly option for shipping lightweight items. Made from thick paperboard material, these mailers provide sufficient protection for items like books, documents, or clothing without the need for excess packaging. Paperboard is a recyclable material, making it an environmentally conscious choice for businesses and consumers looking to reduce their carbon footprint. These mailers are often used for flat items that don’t require extensive cushioning.

Standard White Corrugated Cardboard

Standard white corrugated cardboard mailers offer a classic and versatile packaging solution. These mailers provide the strength and durability of corrugated cardboard, with the added benefit of a clean and professional white exterior. Standard white corrugated mailers are commonly used for shipping a wide range of products, from electronics to clothing. The neutral color allows for easy customization with labels or branding stickers, making them a popular choice for businesses seeking a balance between practicality and aesthetics.


The diverse range of mailer boxes available in the market allows businesses and individuals to choose the most suitable option for their specific shipping requirements. Whether it is the robust protection provided by rigid boxes, the lightweight convenience of bubble mailers, or the eco-friendly appeal of paperboard mailers, there is a type of mailer box for every need. Understanding the unique features and advantages of each type empowers consumers and businesses alike to make informed decisions when it comes to packaging and shipping their valuable items. So, next time you are preparing to send a package, consider the type of mailer box that best fits the contents and ensures a safe and secure journey to its destination.

Frequently Asked Questions

What Is a Mailer Package Type?

A Mailer package type is a compact, lightweight packaging solution typically used for mailing documents, garments, or smaller items. It often comes in envelope-like forms and is suitable for items that don’t require the protection of a traditional box.

What Are the Different Types of Shipping Boxes?

Shipping boxes come in various types, including corrugated boxes, mailer boxes, rigid boxes, and folding cartons. Each type serves specific purposes based on the item’s size, weight, and fragility, ensuring secure transportation.

What Is a Mailer Box?

A mailer box is a compact, self-sealing cardboard box used for shipping smaller items. It provides protection and is an alternative to traditional shipping boxes, ideal for smaller, lightweight products.

What Are the Different Mailer Box Sizes?

Mailer boxes come in various sizes, catering to different product dimensions. Common sizes include small, medium, and large, providing flexibility for various shipping needs.

What Is the Difference Between a Mailer Box and a Shipping Box?

While both serve for shipping, a mailer box is typically smaller, lighter, and self-sealing, suitable for smaller items. A shipping box is more versatile and accommodates a broader range of item sizes and weights.

Is A Mailer a Box or an Envelope?

A mailer is a hybrid between a box and an envelope. It has box-like features but is compact and often made of cardboard, combining the convenience of an envelope with the sturdiness of a box.

What Are Custom Mailer Boxes?

Custom mailer boxes are Personalized Packaging Solutions designed according to specific brand requirements. They can feature unique designs, branding, and tailored dimensions to improve the overall customer experience.

What Is Called Mailer?

The term “mailer” refers to a package or item prepared for mailing or shipping. It can include various types of packaging, such as envelopes, boxes, or bags, used to send items through postal or courier services.

Is A Mailer a Parcel?

Yes, a mailer is a type of parcel. It refers to a packaged item intended for shipping or mailing, encompassing various forms such as envelopes, boxes, or bags.

Why Use Custom Mailer Boxes?

Custom mailer boxes provide a unique branding opportunity, improving the unboxing experience for customers. Tailored designs and branding elements contribute to a memorable and distinctive presentation, fostering brand recognition and customer loyalty.

What Type of Mailer Is Poly?

A poly mailer is a type of mailer made from polyethylene plastic. It is lightweight, water-resistant, and commonly used for shipping clothing, textiles, or non-fragile items that don’t require rigid protection.

Is A Mailer Cheaper Than a Box?

Yes, mailers are generally more cost-effective than traditional boxes. Their lightweight design and reduced material usage contribute to lower shipping costs, making them an economical choice for smaller items.

What Is a Bubble Wrap Mailer?

A bubble wrap mailer is a padded mailer with an added layer of bubble wrap for extra protection. It provides cushioning against shocks and impacts during transit, making it suitable for shipping delicate or fragile items.

What Is the Difference Between Mailer and Email?

A mailer refers to a physical package or item prepared for mailing, while email is a digital message sent electronically. The key distinction lies in the medium—physical versus digital.

What Is a Priority Mailer?

A Priority Mailer is a USPS service offering expedited shipping for packages. It ensures faster delivery compared to standard mail services, making it suitable for time-sensitive items.

What Is the Difference Between Padded and Bubble Mailer?

While both offer extra protection, a padded mailer typically has a softer, padded interior, while a bubble mailer features an additional layer of bubble wrap for improved cushioning against bumps and shocks.

What Is a Commercial Mailer?

A commercial mailer refers to businesses or individuals that send out large volumes of mail, often eligible for discounted postage rates. This category includes bulk mailing services for promotional materials or advertisements.

What Is a Paper Padded Mailer?

A paper-padded mailer is an eco-friendly alternative to traditional padded mailers, featuring a cushioned interior made of recycled paper. It provides protection for items while minimizing environmental impact.

What Package Type Is a Rigid Mailer?

A rigid mailer is a type of packaging with a sturdy and inflexible structure, commonly used to protect flat or fragile items during shipping. It provides a rigid enclosure without the bulk of a traditional box.

What Are Shipping Bags Called?

Shipping bags are often referred to as poly mailers or mailing bags. They are lightweight, flexible, and commonly used for shipping clothing, textiles, or non-fragile items.

What Are Mailer Boxes Made of?

Mailer boxes are typically made of corrugated cardboard, providing a balance of strength and lightweight construction. This material protects the contents while remaining cost-effective for shipping.

What Is a Chipboard Mailer?

A chipboard mailer is a type of packaging made from paperboard or chipboard material. It is rigid and commonly used for protecting flat or lightweight items during shipping.

How Thick Is a Rigid Mailer?

The thickness of a rigid mailer varies, but it is typically between 0.025 and 0.06 inches. This thickness provides the necessary rigidity to protect contents during shipping.

Is A Rigid Mailer an Envelope?

A rigid mailer is similar to an envelope in terms of flatness but offers more structural integrity due to its rigid material. It provides better protection for items compared to a standard paper envelope.

What Is the Difference Between Paperboard and Chipboard?

Paperboard and chipboard are both types of thick paper-based materials, but chipboard is typically more rigid and made from recycled paper fibers, while paperboard is generally thinner and smoother.

Are Rigid Mailers Recyclable?

Yes, rigid mailers are often recyclable, as they are commonly made from materials like corrugated cardboard or chipboard. Recycling practices may vary, so it’s essential to check local guidelines.

What Is the Difference Between Card stock and Chipboard?

Card stock is a thinner, smoother paper, while chipboard is thicker and made from recycled paper fibers. Chipboard is sturdier and more rigid, making it suitable for protective packaging.

How Are Mailer Boxes Made?

Mailer boxes are typically made through a process of cutting and scoring corrugated cardboard sheets. The sheets are then folded and glued to form the box structure, providing a durable and protective packaging solution.

What Is the Best Material for A Mailer Box?

Corrugated cardboard is widely considered the best material for mailer boxes. It offers a combination of strength, durability, and cost-effectiveness, providing optimal protection for shipped items.

What Are Kraft Mailer Boxes?

Kraft mailer boxes are made from Kraft paper, a natural and unbleached material. These boxes are eco-friendly and often preferred for their organic appearance, making them a sustainable packaging choice.

What Are Mailer Bags Used for?

Mailer bags, also known as poly mailers, are used for shipping clothing, textiles, or non-fragile items. Their lightweight and flexible design make them suitable for various products while reducing shipping costs.

What Is a Print Mailer?

A print mailer refers to a promotional or informational piece sent by mail, often containing printed materials such as brochures, catalogs, or advertisements. It aims to communicate a message to a targeted audience through physical mail.

What Is a Mailer in Retail?

In retail, a mailer typically refers to a promotional mailing sent to customers. It may include catalogs, flyers, or discount offers, aiming to engage customers and drive sales through direct mail marketing.

You May Also Like...

Go from beginner to pro with our step-by-step custom box packaging resource guides. Get up to speed on the latest trends and must-know tips about product photography, box templates, box design, retail e-commerce, eco-friendly boxes, shipping strategy, box sizes, branding and more from a trusted industry leader.

Request A Callback