Choose profile by load and span
E-flute keeps compact packs slim with a refined print surface. B-flute adds depth for heavier contents, longer spans, or routes that need more cushioning.
Corrugated ecommerce packaging
Custom mailer boxes engineered for the journey.
Plan flute, print, closure, product fit, flat-pack assembly, and parcel handling as one system—not a graphic wrapped around a stock box.
E / BFlute selected by load
2 sidesInside and outside print
FlatStorage-ready delivery
1:1Physical proof option
Specification before artwork
Four decisions shape the whole mailer.
The right structure depends on what goes inside, how it is packed, where it travels, and what the customer should experience when it opens.
Match process to the artwork
Bold spot-color graphics, fine typography, photographic art, kraft stock, and interior print each point to a different print and liner strategy.
Secure the outbound trip
Roll-end locks, tuck fronts, seal strips, and tear-open features must work with the chosen board, finish, pack-out speed, and return plan.
Start with the packed product. Internal dimensions, weight distribution, and movement control should be set before exterior dimensions and artwork are finalized.
Procurement guide
Choose what the route requires.
These are starting points, not automatic specifications. Packed weight, exact dimensions, artwork, and a physical sample determine the final construction.
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| Decision | Best considered for | Procurement check |
|---|---|---|
| E-flute | Compact DTC packs, fine folds, tighter storage, and a smoother face for detailed graphics. | Confirm the profile supports the packed weight and panel span without bowing or corner collapse. |
| B-flute | Heavier products, deeper mailers, stacking exposure, and routes where extra cushioning is useful. | Allow for thicker edges, a larger folded footprint, and changes to score and locking geometry. |
| Direct print | Clear logos, bold color fields, handling marks, and artwork suited to the board surface. | Review small type, screens, and color expectations on the actual liner—not only on a monitor. |
| Printed liner | Fine illustration, broader color range, photographic detail, or a more controlled retail surface. | Approve the laminated sample after scoring and folding because added layers affect creases and locks. |
| Inside print | Opening instructions, campaign messaging, cross-sell content, or a deliberate unboxing sequence. | Keep key copy away from folds, locking tabs, inserts, and areas hidden by the product. |
Transit engineering
The parcel route belongs in the brief.
A beautiful mailer still fails if the product can move, the lid opens under pressure, or corners collapse in a mixed courier network. The pack-out and route set the performance target.
- Control empty space with a fitted insert, paper support, or a defined void-fill plan
- Keep concentrated weight away from unsupported spans and vulnerable score lines
- Review closure retention after the box is filled, stacked, and handled
- Check printed surfaces for rub, moisture exposure, labels, and shipping marks
Build the product-fit and parcel-test brief or compare outer shipping carton requirements.
Flat-pack economics
Save space without slowing the packing bench.
Roll-end mailers normally arrive flat, reducing empty-box storage and inbound volume. The useful saving comes only when staff can open, lock, fill, and close the box consistently.
- Set score direction and depth for repeatable folding without cracked print
- Balance secure locks against unnecessary force or assembly steps
- Confirm flat dimensions against shelves, cartons, pallets, and packing stations
- Use a pack-out trial to measure assembly flow before a large production run
Sample to production
Approve the structure in the right order.
Fit and folding come first. Print and finish are approved on the structure that will actually be packed and shipped.
Pack-out data
Product size, packed weight, quantity, route, packing method, closure, artwork, and target date.
White sample
Check internal fit, locks, folding order, assembly effort, insert, and product movement.
Printed proof
Review color, registration, key copy, barcodes, finish, scores, and the open-box sequence.
QC + packing
Inspect dimensions, print, glue, scoring, locks, count, flat packing, and export carton protection.
Mailer box FAQ
Questions to settle before production.
Straight answers for buyers comparing structure, print, assembly, and parcel performance.
E-flute gives a thinner profile and a smoother surface for compact ecommerce packs. B-flute has a deeper profile and can provide more cushioning and stacking strength for heavier or more vulnerable products. Final selection should follow packed weight, box span, route, and sample testing.
Yes. Outside print carries shipping and brand information, while inside print can guide the opening sequence or support a campaign. Artwork, board color, print process, and finish should be reviewed together because they change color appearance and fold performance.
Most roll-end corrugated mailers are delivered flat for storage and assembled during pack-out. The dieline must balance quick assembly with secure locks, clean scores, and panels that stay square after folding.
We review product dimensions, packed weight, empty space, insert or void-fill needs, stacking exposure, closure security, and the expected courier route. A physical sample should be packed with the real product and checked against the handling risks that matter to your shipment.
Send the product or internal box dimensions, packed weight, order quantity, print coverage, preferred closure, destination country, target date, and any artwork or reference images. If the structure is not decided, send the product details and we can start from the pack-out.
Quote a custom mailer
Start with what goes inside.
Send the product size, packed weight, quantity, destination, and reference artwork. Kevin will reply with the structural questions needed for a useful quote.