Your most Googled questions about custom mailer boxes, answered

In an age where brand storytelling is more important than ever, generic, unrecognisable packaging just isn’t making the cut for consumers. Today’s shoppers - especially in the world of retail and e-commerce - crave more than just the product they’ve purchased, and shopping has become a physical experience from the offset that begins with custom packaging. 

For brands like the beauty giant Glossier, incorporating instantly recognisable packaging enhances the consumer experience from the get go, turning ordinary deliveries into memorable moments. Custom mailer boxes like these not only elevate brand identity, but also enhance functionality, offering sturdy and eco-friendly protection for products!

Whether you’re a growing brand or established name, delivering bespoke packaging boxes is a surefire way to draw attention and leave a lasting impression. But what else do people really want to know about it? Let’s unpack your most Googled questions around custom mailer boxes. 

Why are custom mailer boxes safer than stock boxes?

With the number of consumers experiencing damaged online deliveries climbing by over a third last year, finding a bespoke solution, like custom inserts tailored to your product’s size, significantly reduces movement during transit. Utilising custom mailer boxes as opposed to a “one-size-fits-all” approach is becoming increasingly important among brands, and leaving a positive impression on consumers. 

What type of boxes are suitable for shipping purposes?

It’s an all important question when preparing to deliver to your consumers. And the answer? It depends on the products you’re shipping. Let’s break down the types of board grade you can choose from.

Ideal for small boxes and letterbox-friendly items, E-flute cardboard boxes are durable and crush resistant with a smooth, clay-coated finish - perfect for printing your company’s branding directly onto the surface. 

Most commonly used for postal boxes, B-flute cardboard helps to cushion items during the shipping process and can also be printed, albeit with a less smooth finish than E-flute. 

The best of both - EB grade cardboard provides the strength of both flutes, the ideal option for shipping fragile and/or heavy items. Some box styles of this cardboard grade are so sturdy, they can support the weight of a person! 

Can custom design cardboard boxes be used for shipping?

The short answer is - yes! Not only are custom cardboard boxes specially designed to be strong and durable, they can also be tailored to your product’s needs, reducing internal movement and the chance of breakage while travelling. What’s more, there’s also the option to add foam inserts during the shipping process, providing an extra barrier of protection.

Unlike plastic alternatives, custom cardboard boxes can also be a more sustainable method for shipping, with the option to use recycled materials that reduce environmental impact and naturally biodegrade after your customer has received their order. 

How to customise printed mailer boxes for my business?

Once you’ve opted for custom mailer boxes as your method of delivery, it’s important to consider packaging that best reflects your brand. 

This includes thinking about your product’s size, shape and structure (remember, your mailer should fit the product snugly to avoid any damage!), incorporating your brand logo, colours, typography and imagery for brand consistency, and selecting the right materials that align with your budget, sustainability goals and shipping needs. Some businesses like the luxury jewellery brand, Boodles, even choose to keep external branding minimal or move it entirely inside the box - a smart move for reducing theft risk during delivery.

Struggling to picture your perfect packaging? Check out our blog, 5 examples of brands using custom mailer boxes to stand out, for some inspiration. 

Can retail product boxes be used for shipping?

It can! But only if it’s designed with transit in mind. While individual retail product packaging (such as elegant cartons or branded boxes) is often made to look great on shelves, it’s not always built for the rigours of shipping. Lighter product packaging boxes may lack the structural strength and sealing needed to protect products during handling and delivery.

That said, with the right approach, product packaging can do both. For example, we created packaging for Aegle’s premium supplements using Gmund Heidi board paired with a corrugated inner fitment to protect glass jars in transit, keeping the product safe.

When packaging is both brand-led and structurally sound, it can elevate unboxing while reducing damage and returns -  the best of both worlds.

How to choose the right size box for shipping?

Finding the right sized packaging to fit your product keeps things low-cost and environmentally friendly due to a significant reduction in waste and shipping costs. Measuring your product accurately and assessing its fragility and weight are important steps to take when choosing the right size of product packaging, and our expert team is on hand to offer tailored advice to ensure your custom mailer box hits the mark. 

For brands shipping internationally, it’s also important to consider volumetric weight - the pricing method many couriers use based on the space a parcel takes up, not just its actual weight. Choosing packaging that’s optimised for both size and shape can significantly reduce your carriage costs.

We’re highly experienced in advising on custom packaging that’s optimised for your product’s size and shape. For volumetric shipping in particular, we can help you design a ​​space-efficient box tailored to your needs, ensuring it meets the dimensional requirements of major carriers like DHL, FedEx, and UPS, keeps costs down and puts a smile on your customers' faces! 

Ready to find the perfect product packaging for your brand? Explore our custom mailer boxes and get in touch with the team…