Need further assistance?If you are looking for some additional information or support, feel free to get in touch with our packaging experts & sales team.
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Mailer Boxes With Inserts
Custom mailer boxes with inserts offer secure product placement and premium unboxing. Perfect for gifting, branding, and shipping delicate or high-end itemsA Customized Packaging Experience For your Branding Needs
Design & ProtectionAdd Secure insert design keeps items organized and protected during transit | Material CompositionCorrugated cardboard with E, B, or C flute and custom insert options | Structure & BuildFoldable, self-locking mailer with precision-fit inserts |
Paperboard InsertSturdy paperboard or corrugated stock. Ideal for lightweight to medium products | Foam InsertEVA or EPE foam insert with superior cushioning and elegant product presentation | Blister InsertTransparent thermoformed for secure fit and retail visibility |
Printing MethodOffset or litho-laminated for sharp, vibrant color reproduction | PantoneAccurate color control to match brand-specific shades. | CMYKFull-color process for detailed artwork and premium designs |
All You Need to Know About Custom Mailer Boxes with Inserts
Designed for unforgettable unboxing, these mailer boxes with inserts keep every item secure and perfectly displayed—turning every opening into a brand experience
StructureMulti-Layer Laminate with Bottom GussetPET provides print gloss; AL or MET-PET blocks oxygen; PE seals and provides flexibility. Gusset expands to stabilize filled stand up pouches
Construction TechniquesSealing and Gusset FormingK-seal or round-bottom gussets is created via heat sealing for balanced standing. Side seals welded with ±1 mm tolerance for even load distribution.
ApplicationsFunctional Enhancements for UsabilityOptions include ziplocks, spouts, tear notches, degassing valves, and hang holes. Combine matte + gloss finishes or add spot foiling for retail appeal.
Making Your Brand Unforgettable
Need Help Designing Your Stand-Up Pouch?
We provide free in-house design support
Frequently Asked Questions
Get answers to common questions about custom rigid boxes, or visit our Help Centre for further information.Are inserts custom-sized for each product?
Yes, inserts are die-cut or molded according to exact product dimensions to ensure secure placement and minimal movement. You can use one or multiple types of inserts
Are mailer boxes with inserts suitable for fragile items?
Yes, especially when paired with foam or molded pulp inserts for impact absorption. You can get in touch with our production team to get more information about your best options for shipping.
What flute type is best for mailer boxes with inserts?
E-flute is commonly used for retail presentation, while B-flute or double wall is recommended for heavier products.
What is the production time for customized mailer boxes?
Production typically takes 10–14 business days after final artwork and structural approval by the client. In case of urgent requests, please get in touch with our sales team.
