Product family 03
Corrugated mailers
Die-cut shippers in single-wall or double-wall board, sized to the product instead of padded around it. Used where the outer carton is also the unboxing moment, or where a courier route needs more protection than a folding carton can give.
Specifications
Flute grades, and what each one actually survives.
| Parameter | Range we produce | Notes |
|---|---|---|
| Board grade | E-flute (1.5 mm), B-flute (3 mm), BC double wall (6–7 mm) | E-flute for retail finish, BC for long-haul parcels |
| Fluting | A-flute / B / C / E / BC, in kraft or white top liner | White top liner lets you print fine detail |
| Finished size | Up to 600 mm unfolded on the longest panel | Larger sizes need a hand-glued construction |
| Style | Roll-end tuck, one-piece folder, crash lock, mailing box with peel strip | Peel-and-seal strip on request, self-adhesive |
| Flexo 1–2 colours, or litho-laminated full CMYK | Litho lamination adds cost but keeps photography crisp | |
| Insert | Corrugated fitment, pulp tray, foam, or a printed paperboard sleeve | Cut in-house so the mailer and insert fit together |
| MOQ | 1,000 pcs for flexo; 2,000 pcs for litho-laminated | Below 1,000 we quote a stock mailer with a label |
| Sampling | 5–8 working days, plain or flexo printed | Plain sample first to check the product fit |
| Production lead time | 20–30 days after sample sign-off | Litho lamination sits at the top of the range |
| Packing | Shipped flat in bundles, palletised with edge protection | Flat mailers store in very little warehouse space |
Flute grade is the single biggest driver of both protection and price. Going up from E-flute to double wall typically doubles the board cost but can remove an inner insert.
Where a corrugated mailer is the right answer
- E-commerce shipmentsWhere the parcel is the first physical contact with the brand
- Subscription boxesMonthly recurrence with a changed print, same die
- Heavy or bulky items5–20 kg where a folding carton would fail
- Export master cartonsShip-ready cases that double as the retail outer
Where it is the wrong spend
- Counter retailCorrugated reads as a shipping material, not a shelf pack
- Small quantitiesBelow 1,000 pcs the die cost per unit gets unreasonable
- Very small productsA 60 mm item in a corrugated box looks lost
- Air freightVolume is the cost driver, and single wall is mostly air
Sampling
Request a mailer sample.
Tell us what goes in the box, its weight and how it will ship. We cut a plain sample first to confirm the fit, then quote the print once the die is fixed.
If you already have a courier damage rate, mention it — that number tells us which flute grade to start with.
- Phone+86 188 1391 9413
- Emailcrystal1319@163.com
Questions we answer daily
Corrugated mailer FAQ
Which flute grade for a 3 kg product?
B-flute single wall is usually enough for a 3 kg item inside a rigid inner pack. E-flute with a fitment is thinner and cheaper but relies on the insert to take the load. We confirm on the plain sample rather than guessing from the weight alone.
How do you test the drop performance?
We can run an in-house drop test at heights agreed with you, usually the ISTA 1A or 3A sequence used by your retailer, and report which corner failed. This is not a certified ISTA laboratory report unless we commission it externally, and we will say so in writing.
Can the mailer be recycled as one item?
Yes, if the closure is water-based adhesive tape and the insert is pulp or corrugated. A peel-and-seal strip with a plastic liner, or a foam insert, means the parcel is not single-material and that changes the recycling claim on the EU market.
What artwork do you need for flexo printing?
Vector artwork with spot colours defined, at least 300 dpi for any raster element, with 10 mm clearance from the die line. Flexo registration is looser than offset, so thin reverse-out type under 6 pt is worth checking on the sample first.
Can you supply the outer carton only?
Yes. Plenty of clients print the retail box elsewhere and buy the shipper from us. Send the internal dimensions and the stacked weight and we will confirm a board grade, with the overhang and clearance already calculated.
Shipping damage you keep paying for?
Send the product weight, the current carton size and where parcels are failing. The reply is a flute recommendation with a quote, not a catalogue.