Corrugated Mailer Boxes

Custom corrugated mailer boxes offer the strongest protection in ecommerce packaging — built with a fluted inner layer that absorbs impact and resists crushing under stacking pressure. Ideal for heavier products, long-distance shipping, and anything that needs to arrive in perfect condition. Fully printed in any colour with custom sizing available.

• Single and double wall corrugated board options
• Crush-resistant fluted structure absorbs transit impact
• Full-colour exterior and interior printing
• Custom dimensions for any product size
• Eco-friendly, recyclable materials

For maximum protection on fragile items, see our double wall cardboard mailer boxes.

Not All Mailer Boxes Are Created Equal

Thin paperboard mailers look tidy on a shelf but fold under pressure. If you ship anything with weight, fragility, or distance — you need corrugated. The fluted inner layer of a corrugated mailer box isn’t just filler; it’s an engineered shock-absorption system that has protected products in global shipping chains for over a century.

At The Mailer Boxes, we manufacture corrugated mailer boxes in single-wall (B, C, and E flute) and double-wall configurations, matched to your product weight and shipping route. Every box we produce combines structural engineering with clean, high-quality printing — so protection and presentation never have to compete.

Understanding Corrugated Board Grades

E-Flute (1.5mm)

The finest corrugated option. Thin enough for clean print registration, strong enough for lightweight product shipping. Popular in cosmetics, jewellery, and food packaging where presentation matters as much as protection.

B-Flute (3mm)

The most versatile corrugated grade. Handles medium-weight products, stacks well, and prints cleanly. The standard choice for most ecommerce mailer applications.

C-Flute (4mm)

Heavier-duty than B-flute, offering greater cushioning for fragile or heavier items. Preferred for products that ship in larger boxes where structural integrity across the panel span matters.

Double Wall (6–8mm)

Two fluted layers bonded together for maximum crush resistance. Essential for heavy machinery parts, bulk shipments, or anything that will be stacked under significant weight in transit. Explore our dedicated double wall mailer boxes range for these applications.

Why Corrugated Beats Chipboard for Shipping

Chipboard — or rigid grey board — is flat. It resists bending but offers no cushioning. A chipboard box dropped from 1 metre transfers the full impact force directly to your product. Corrugated board compresses in the fluted layer, converting impact energy into deformation of the board rather than damage to the product. For anything fragile, corrugated is the only responsible choice.

See how our chipboard mailer boxes compare if your application is rigid presentation packaging rather than transit shipping.

Industries That Rely on Corrugated Mailer Boxes

• Electronics and tech accessories — shock-sensitive products need fluted protection
• Glassware and ceramics — fragile items that can’t arrive cracked
• Automotive parts — heavy, sharp-edged components need structural containment
• Subscription services — consistent, cost-effective monthly shipping
• Industrial suppliers — bulk small-parts shipments to trade customers

Frequently Asked Questions

What is the weight limit for single-wall corrugated boxes?

Single-wall B-flute is rated for most products up to approximately 15 kg. Heavier loads should use double-wall board. Contact us with your product weight and we’ll recommend the appropriate grade.

Can corrugated boxes be printed in full colour?

Yes. We print directly onto the corrugated liner using high-quality flexographic or digital printing processes. Colour registration on E-flute is particularly clean — comparable to solid board printing.

Are corrugated boxes recyclable?

Corrugated cardboard is one of the most recycled materials globally. Our boxes are made from post-consumer recycled fibre and are fully kerbside recyclable.

Build Stronger Shipping into Your Brand

A box that arrives intact is one a customer opens with a positive expectation. Request a quote for corrugated mailer boxes today and let our team help you choose the right specification for your products.