Corrugated Cardboard Mailer Boxes
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Corrugated Cardboard Mailer Boxes give your business the branded materials it needs to leave a lasting impression. Custom design and bulk pricing available on every order. Place your order now and save with wholesale rates!
$0.98
UNLIMITED CUSTOMIZATION OPTIONS
A printing technique employing a plate to transfer designs onto paper. Ideal for extensive print jobs.
Plate-free digital printing transfers designs electronically, cost-effective for short runs.
Screen printing is a method using a mesh screen and stencil to transfer ink onto a substrate.
Quick-drying printing technique utilizing ultraviolet lights for ink curing, yielding a glossy finish.
Consisting of water-based pigments, Ensures top-notch color output with a 100% eco-friendly profile.
Fluorescent inks are vibrant, UV-reactive pigments that emit vivid colors under ultraviolet light.
Generate pure colors using specific ink formulas to consistently & precisely reproduce color in printing.
Produce metallic colors through precise ink formulations to replicate color in printing.
Premium bleached white paperboard, specially coated on one side to enhance printing & finishing.
Bleached white paperboard, coated on both sides to achieve superior printing quality and finishes.
Top-notch textured paper, perfect for adding a touch of style when wrapping up durable boxes.
A unique paper material showcasing a shiny or matte metallic laminated surface.
Bleached kraft paper crafted from a blend of new and recycled pulp, coated on both sides for optimal printing.
Kraft paper produced from a combination of new and recycled paper pulp, with coating on both sides for printing purposes.
Kraft paper dyed black, manufactured from a blend of new and recycled pulp, and coated on both sides for printing applications.
Crafted from recycled grey chipboard cardboard, also known as uncoated recycled paperboard, ideal for luxury rigid boxes.
Unique paper material showcasing a holographic laminated surface in either glossy or matte finish.
Grey chipboard, one-sided white cardboard with a smooth, printable surface, ideal for luxury rigid boxes.
Gloss lamination enhances visual appeal by applying a shiny finish, and protecting printed materials.
Matte lamination offers a non-reflective finish, providing elegant appearance to printed materials.
Made with a smooth lamination that feels like touching a peach, can choose between a satin or matte.
A UV coating is applied to a specific area and then cured using ultraviolet light to make it sturdy.
A transparent coating is applied using the CMYK printing technique, and it comes in gloss, satin, or matte.
A fast-drying coating that undergoes curing through ultraviolet light is offered in both gloss and matte.
In a printing method, dies are pressed onto the back of the material to create a raised motif.
A printing technique that involves pressing dies onto the front of the material to create a raised motif.
In foil relief printing, foil is transferred at high temperatures, often employing multiple colors.
Craft a die-cut shape with a plastic film layer, revealing a window to showcase the product inside.
We recommend the ideal material and add-ons like lamination, foiling, embossing UV, etc.
Get Free Design Support with your box 3d Renders or Send Your Design File for Printing.
Upon design approval, we’ll print and conduct quality checks before shipping the boxes to you.
Technical Specifications
| Dimensions | Available in Custom Sizes |
| Printing | CMYK, Pantone Color, Full Color & No Printing |
| Paper Stock | Eco-Friendly Kraft, Corrugated Cardboard & Premium Rigid Stock |
| Coating | Semi-Gloss AQ, Gloss UV, Matte UV & Spot UV |
| Default Process | Die Cutting, Gluing, Scoring, Perforating |
| Custom Options | Window Cut Out, Gold/Silver Foiling, Embossing, Raised Ink |
| Proof | Digital Proof, 3D Mock-Up |
| Shipping | Shipped FLAT (Free Shipping Across USA & Canada) |
| Help | For further inquiries and Quotes, contact us or email at sales@cratpackaging.com |
Corrugated cardboard mailer boxes combine fluted corrugated board with reinforced wall construction, built for wholesale buyers who need more crush resistance and stacking strength than a standard single-wall mailer offers. The compound name describes the material itself: true corrugated cardboard has a wavy fluted layer glued between two flat liner sheets, not the flat solid board used in lightweight folding cartons. Crat Packaging manufactures corrugated cardboard mailer boxes at its own US facility, with double-wall options for heavy or fragile shipments, full-color printing, and MOQs starting at 100 units.
Why Choose Our Corrugated Cardboard Mailer Boxes
- True corrugated construction — a fluted medium bonded between liner sheets gives real crush and stacking resistance, unlike flat chipboard or paperboard mailers.
- Double-wall option for heavy loads — two fluted layers combined for extra-fragile or heavy products that exceed what single-wall corrugated cardboard can safely handle.
- Higher ECT ratings on request — we can spec board strength (edge crush test) to match your product weight and the distance it needs to travel.
- Self-locking, tape-free assembly — tuck-style and roll-end closures fold shut without tape, cutting pack-out time on the warehouse floor.
- Full CMYK printing inside and out — unlimited colors at no extra charge, plus matte or gloss lamination, spot UV, and foil stamping.
- US-sourced, recyclable board — corrugated cardboard produced domestically and fully recyclable after use.
- Custom inserts and dividers — corrugated or foam inserts keep multiple items, glass, or ceramics from shifting inside the reinforced shell.
Specifications
| Attribute | Details |
|---|---|
| Box Style | Corrugated cardboard folding mailer, single-wall or double-wall; see also corrugated mailer boxes or tuck top mailer boxes |
| Dimensions | Fully custom; typical range 4″ x 4″ x 2″ to 24″ x 18″ x 10″ |
| Material | E-flute or B-flute corrugated cardboard, single-wall standard, double-wall for heavy-duty runs; kraft or white liner |
| Wall Construction | Single-wall (one fluted layer) or double-wall (two fluted layers) for added crush resistance |
| ECT / Strength | Standard single-wall around 32 ECT; double-wall builds spec higher for heavier or stacked freight |
| Printing | Full CMYK, PMS spot color, digital or offset, single- or two-sided |
| Finishing | Matte or gloss lamination, spot UV, foil stamping, embossing/debossing |
| Add-ons | Window cutouts, corrugated or foam inserts, handles |
| Minimum Order | 100 units |
| Turnaround | 10–15 business days standard; 8 business days expedited |
| Setup / Plate / Die Charges | Free |
Customization Options
Single-Wall vs. Double-Wall Corrugated Cardboard
Single-wall corrugated cardboard mailer boxes use one fluted layer and handle most e-commerce and retail shipments efficiently. Double-wall construction adds a second fluted layer for products that need real impact protection — glassware, electronics, industrial parts, or anything shipping through multiple sorting hubs where a box gets stacked, dropped, or compressed under pallet weight.
Flute Selection
E-flute (about 1/16″ thick) keeps the box compact and gives the sharpest print surface for lighter items. B-flute (about 1/8″ thick) trades some print detail for meaningfully more crush resistance on heavier or bulkier products. We help you match flute and wall count to your actual product weight rather than guessing.
Sizes
Boxes are die-cut to your exact product footprint instead of a fixed size chart, so you’re not paying to ship excess air or risking a product shifting inside an oversized box.
Printing & Finishing
Full CMYK printing covers the box inside and out at no added color cost, with PMS spot color matching available for exact brand-color consistency. Matte or gloss lamination, spot UV, foil stamping, and embossing/debossing all add a premium finish on top of the reinforced board.
Inserts & Add-Ons
Corrugated or foam inserts and dividers hold multiple items, glass, or ceramics in fixed positions inside the box, which matters more on double-wall builds carrying heavier or more fragile contents.
Industries & Use Cases
Manufacturers and B2B distributors rely on this reinforced construction for bulk product shipments where stacking strength during warehouse storage matters as much as transit protection. Beauty, food, and beverage brands use double-wall builds to protect glass bottles and jars moving through freight networks. Electronics and hardware companies use the reinforced construction to ship components and parts without secondary outer cartons, while subscription box and gift companies use the added durability for multi-item sets crossing long shipping routes.
How to Order
- Send us your product dimensions, approximate weight, and target quantity for a free quote.
- We recommend a flute type and wall count — single or double — based on your product’s weight and fragility.
- Our design team builds a free dieline and digital proof; physical samples available on request.
- Approve the proof and production begins, running 10–15 business days standard or 8 days expedited.
- Boxes ship flat-packed to keep freight costs down and assemble quickly on your line.
Why Wholesale Buyers Choose Crat Packaging
Crat Packaging produces corrugated cardboard mailer boxes at our own US facility, so wall construction and flute grade stay consistent from your first order to your thousandth. There are no setup, plate, or die-cut charges, design support is free, and the minimum order is 100 units. Bulk pricing starts from around $0.75 per unit, depending on size, material, quantity, and finishing.
Frequently Asked Questions
What does the term “corrugated cardboard” actually mean?
It’s the fluted board itself — a wavy paper medium glued between two flat liner sheets. This term specifically describes that three-layer construction, as opposed to flat solid board used in lightweight cartons that has no fluted layer at all.
When should I choose double-wall over single-wall?
Double-wall corrugated cardboard makes sense for heavier products, glass or ceramic items, or shipments that pass through multiple handling and sorting points where crush resistance matters most. Most standard e-commerce shipments do fine on single-wall.
How much weight can a corrugated cardboard mailer box hold?
It depends on flute type and wall count. Single-wall E-flute typically handles items up to roughly 20–25 lbs, B-flute up to 30–40 lbs, and double-wall builds go higher — tell us your product weight and we’ll spec the right construction.
Is corrugated cardboard recyclable?
Yes. Our corrugated cardboard is US-sourced and fully recyclable, accepted by most curbside recycling programs as standard cardboard.
Can these boxes be printed inside as well as outside?
Yes. Full CMYK printing can cover both the exterior for shipping impact and the interior for a branded reveal when the box opens — mention it at the quote stage so we can price the extra print pass.
What’s the minimum order quantity?
Our minimum order is 100 units with no setup, plate, or die-cut charges added to your quote.
Need a corrugated cardboard mailer box built to survive real freight handling? Get a free quote from Crat Packaging today.
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