Custom Mailer Boxes Built for Branding and Protection

Your mailer box is the first physical touchpoint your customer has with your brand. At Pro Custom Packaging, we supply custom mailer boxes designed to protect your products in transit and deliver a premium unboxing experience that keeps customers coming back.

Whether you need personalised mailer boxes for a PR gifting campaign or high volumes of printed mailer boxes for your e-commerce operation, every order is produced to the same exacting standard — full-colour print, your choice of finish, and delivery across the UK in 7-14 working days.

How Our Custom Mailer Boxes Are Constructed

Understanding what goes into a mailer box helps you make the right choice for your product. Our custom mailer boxes are built as follows:

• Core: E-flute corrugated board — a fine, tightly-fluted corrugated layer that provides structural rigidity and absorbs impact during transit without adding unnecessary bulk
• Outer layer: 220gsm cardboard laminated to the outside of the corrugated core, creating a smooth, print-ready surface. This gives you a 3-ply construction — strong, clean, and ideal for full-colour printing
• Inner layer (optional): If you choose inside printing, a further 220gsm card is laminated to the interior, creating a 4-ply box. This inner layer provides a clean, branded surface for your message, artwork, or colour when your customer opens the box
• Kraft finish option: If you prefer a natural kraft aesthetic, we paste kraft card to the outer layer instead of standard cardboard — giving the same structural integrity with the distinctive brown kraft look

This construction means your custom mailer boxes are genuinely protective as well as visually impressive — not just a printed shell around a flimsy structure.

Printed Mailer Boxes

Outside Print Only

Full-colour print on the exterior of your mailer box — your logo, brand colours, and messaging on the outside surface. A clean, professional result at an efficient price point. Best for brands prioritising impact at the moment of delivery.

Outside and Inside Full-Colour Print

The complete unboxing experience. A 220gsm inner lining is added (4-ply construction), giving a fresh print-ready surface inside the box. When your customer opens it, they see your brand world — a thank-you message, product care instructions, a bold colour, or full artwork. This is the choice of subscription box brands, beauty companies, and lifestyle brands who want every touchpoint to feel considered.

Finishing Options for Personalized Mailer Boxes

The finish applied to your printed mailer boxes is what elevates them from functional to memorable:

• Gloss Lamination — vivid, high-sheen finish that makes colours pop
• Matte Lamination — soft, tactile, understated luxury feel
• Spot UV — selective high-gloss coating over your logo or specific design elements
• AQ Coating — aqueous protective coating, a robust finish without plastic lamination
• Soft-Touch Lamination — velvety texture popular in premium cosmetics and gifting
• Embossing / Debossing — raised or recessed logo or text for a tactile, high-end impression
• Foil Stamping — gold, silver, or coloured metallic foil for standout visual impact

Not sure which finish suits your brand? Our team has advised businesses across cosmetics, fashion, food, and retail — get in touch and we will recommend the right combination for your product and budget.

Personalised Mailer Boxes: Fully Tailored to Your Brand

Every brand is different, and your packaging should reflect that. Our personalised mailer boxes are produced to your exact specifications — no standard templates, no compromises on colour accuracy, no off-the-shelf sizes.

• Custom dimensions — sized to fit your product precisely, reducing void fill and ensuring a clean presentation
• Pantone colour matching — your brand colours reproduced accurately, not approximated
• Kraft or cardboard outer — choose the surface material that matches your brand aesthetic
• Bespoke structural additions — inserts, dividers, and tear strips available on request
• Digital proof before production — you receive a full digital prototype for approval before any box goes into production.

Who Uses Custom Mailer Boxes

E-Commerce and Online Retail

Every order you dispatch is a brand impression. Custom mailer boxes replace plain shipping cartons with something customers photograph, share, and remember — at a realistic cost per unit for e-commerce volumes, so the ecommerce packaging cost also stays within the budget.

Subscription Box Businesses

Monthly subscription services depend on the unboxing experience. Our printed mailer boxes with inside print are a staple for subscription brands across beauty, food, wellness, and lifestyle.

Cosmetics and Beauty Brands

Finish and colour accuracy matter enormously in beauty packaging. Soft-touch lamination, spot UV on your logo, and Pantone-matched colours ensure your packaging is as premium as the product inside.

Fashion and Apparel

Our custom mailer boxes are popular with boutique clothing brands and online fashion retailers who need apparel packaging that is both protective and cost-effective. View our apparel packaging range for further options suited to garments and accessories.

PR Kits and Corporate Gifting

Influencer mailer boxes, press kits, and corporate welcome packages all require packaging that makes an impression on opening. We have supplied bespoke PR mailer boxes to brands and agencies across the UK.

Why Brands Across the UK Choose Pro Custom Packaging

Genuine Packaging Expertise

We specialise in custom packaging boxes — not general printing. That means when you ask about construction, material performance, or print processes, you get an informed answer from someone who works with these products daily. We understand the difference between a box that looks good in a photo and one that survives a courier network.

Digital Proofing for Total Confidence

Before any order goes into production, you receive a full digital artwork showing exactly how your finished mailer box will look — colours, print placement, dimensions, and finish. You approve it before we produce a single box.

Transparent, Fixed Pricing

The price quoted is the price you pay. No artwork fees added at checkout, no surprise delivery charges added later.

Free Artwork Preparation

Our design team prepares your files for print, checks all technical specifications, and produces your digital proof — at no additional charge.

UK-Wide Delivery

We deliver custom mailer boxes to businesses across the UK. Delivery is included in your quoted price, and full tracking is provided once your order is dispatched.

Dedicated Point of Contact

You will have a named contact throughout your order — direct communication, no call centres, no support tickets.

How to Order Custom Mailer Boxes

1. Request a Quote — Tell us your required dimensions, quantity, print scope (outside only or outside and inside), and preferred finish. We will send a fixed, itemised quote within one business day.
2. Artwork and Digital Proof — Send us your logo and brand assets, or let our design team prepare your artwork. We produce a full digital prototype for your review and approval before production begins.
3. Production — Once your proof is approved, production starts immediately. Our standard lead time is 7-14 working days from proof sign-off to dispatch.
4. UK Delivery — Your order is delivered directly to your address anywhere in the UK. Tracking information is sent on dispatch.

Frequently Asked Questions About Custom Mailer Boxes

What is the minimum order quantity for custom mailer boxes?

Our minimum order quantity for custom printed mailer boxes is 100 units. This applies across all material and print configurations.

How long do custom mailer boxes take to produce?

Our standard production lead time is 7-14 working days from digital proof approval to dispatch.

Can I see what my mailer box will look like before production?

Yes. Every order includes a full digital prototype proof showing your artwork applied to the box, including colours, print placement, and finish. Production does not begin until you have reviewed and approved this proof.

Can you print on the inside of the mailer box?

Yes. Inside printing requires a 220gsm inner lining to be added to the box construction, creating a 4-ply box. This gives a clean, print-ready surface on the interior. The option is available on all our custom mailer boxes.

What is the difference between 3-ply and 4-ply construction?

A 3-ply mailer box has an E-flute corrugated core with a 220gsm cardboard outer — printed on the outside only. A 4-ply box adds a 220gsm inner lining, enabling full inside printing and adding an extra layer of rigidity. If you want inside print, you need 4-ply.

Can I have a Kraft finish on my mailer box?

Yes. We paste kraft card to the outer layer instead of standard cardboard, giving the same E-flute corrugated structure with a natural brown kraft surface. Kraft is popular with eco-conscious brands and artisan product companies.

What artwork format do you need?

We accept PDF, AI, and EPS files at 300 DPI in CMYK colour mode with 3mm bleed on all sides. If you do not have print-ready artwork, our design team can prepare it from your logo and brand guidelines at no extra charge on order confirmation.

Do you deliver custom mailer boxes across the UK?

Yes. We deliver to all UK mainland addresses. Delivery is included in your quoted price. Tracking information is provided on dispatch. For large-volume or multi-location deliveries, discuss your requirements at the enquiry stage.

Order Your Custom Mailer Boxes Today

Tell us your size, quantity, print scope, and preferred finish and we will come back to you within one business day with a fixed quote and confirmed lead time.