Custom corrugated mailer boxes

Built around the product. Not around a stock box.

Structure, board, print method, insert and pack-out—developed as one working system for launch kits, samples, e-commerce and multi-location programs.

Send project specs Request samples

Have a dieline? Send it over. Need one? Start with product dimensions, weight and quantity.

Open Wild and Organic custom corrugated mailer box with six coordinated product cartons and printed literature
Coordinated packaging system Corrugated mailer · fitted contents · printed literature

01 Structure & fit

02 Inside / outside print

03 Inserts & components

04 Kitting & distribution

Choose the right construction

Mailer box or folding carton?

They can share graphics and finishing, but they solve different packaging problems. The first decision is structural—not visual.

Corrugated mailer box

Protection, presentation and shipping structure.

  • Fluted corrugated construction, often E-flute or another grade selected for the application
  • Commonly used for kits, samples, e-commerce, onboarding and product launches
  • Can incorporate corrugated or paperboard inserts, literature and multiple components
  • May print outside only or inside and outside, depending on the production path

A presentation mailer may still require an outer shipping carton. Carrier handling and product protection should be reviewed before it ships as-is.

Folding carton

Lightweight paperboard for retail and product containment.

  • Single-ply paperboard such as SBS or another specified folding-carton stock
  • Typically used for retail shelves, bottles, cosmetics, food, supplements and smaller products
  • Common structures include straight tuck, reverse tuck, auto-lock and seal-end cartons
  • Well suited to foil, embossing, coatings, laminations and other premium treatments
View folding cartons

A spec-driven approach

Start with what the box has to do.

The print matters. So do the product, shipping environment, assembly time and the way the recipient opens it.

01

Product & pack-out

Inside dimensions, weight, orientation, component count, literature and the amount of open space all affect the structure.

02

Structure & board

Roll-end mailers, custom die-cut forms, flute, liner and insert style are selected around fit, handling and presentation.

03

Graphics & print path

Coverage, run length, board and color expectations guide the choice between practical direct, flexographic or laminated print paths.

04

Assembly & distribution

Flat delivery, assembled boxes, kitting, versioning, outer cases and multiple destinations should be planned before production.

Open corrugated mailer concept with a die-cut insert and printed interior
Interior graphics and a purpose-built insert can turn one box into a complete presentation.
White Execuprint corrugated mailer box photographed close up
Clean exterior, controlled structure.
Open corrugated box concept showing an internal structural frame
Fit and retention begin with the contents.

Build the right specification

Options that support the job—not a menu of upgrades.

Every choice should earn its place through protection, appearance, production efficiency or the recipient experience.

Board

White or kraft liners; flute and grade selected around size, weight, print and handling.

Structure

Standard roll-end mailer forms or a custom die-cut construction when the product calls for it.

Printing

Outside only or inside/outside; process and spot-color expectations reviewed against the board and quantity.

Surface

Coatings or laminations may be considered where compatible with the chosen print and converting path.

Insert

Corrugated, paperboard or another practical retention method developed around product geometry and presentation.

Pack-out

Literature, labels, cartons, samples and versioned components assembled into one controlled kit.

Wild and Organic custom mailer kit with six coordinated product cartons and a brand deckClose crop of a Wild and Organic open mailer with coordinated contents

Selected work · Wild & Organic

One coordinated packaging system.

The corrugated outer piece, coordinated folding cartons, fitted presentation and printed brand deck work together as one kit—not as separate purchases.

Outer
Printed corrugated mailer
Inside
Product retention and organized presentation
Components
Coordinated cartons and printed literature
Planning
Structure, graphics and pack-out considered together

Where mailers fit

More than an e-commerce box.

Use a mailer when the box has to organize, protect and present multiple elements as one deliberate experience.

01

Launch & PR kits

A controlled presentation for media, creators, sales teams or key customers.

02

Samples & swatch kits

A fitted structure that keeps components organized and easy to review.

03

E-commerce & subscription

A branded arrival experience built around the product and shipping plan.

04

Dealer & sales kits

Products, collateral and instructions packed as one coordinated unit.

05

Multi-location programs

Versioned kits prepared for stores, branches, events or field teams.

06

Onboarding & presentation

A more substantial alternative to a paperboard presentation carton.

Ready when you are

Send the brief you have.

Complete specs are welcome. If the construction is still open, send the product dimensions, weight, quantity and intended use. We’ll help organize the next decisions.

Request a quote Email Customer Care

Prefer to talk? 661.220.5213

Useful details to include

  • Inside dimensions and product weight
  • Quantity, versions and repeat cadence
  • Ship-as-is or overpack requirement
  • Outside-only or inside/outside graphics
  • Insert, literature and pack-out needs
  • Required date and delivery locations