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Custom Mailer & Shipping Box

In this era of E-commerce, In The Bag has proudly produced mailers for a wide range of companies, that are as eco-friendly as they are inviting. The mailer serves the dual purpose of shipping carton and product package, and is the e-comm consumer’s “first impression” of your brand. Our corrugated products are designed to ensure that your products reach their destination in peak form and looking good. There are options available for a variety of quantities and budgets. Materials are recycled and recyclable, readily available in Kraft or White, and can be creatively designed and printed to make an impression. 

What is a Mailer & Shipping Box?

A mailer is generally a 1-piece box made of corrugated cardboard, which can be easily assembled into an attractive product box that can also be used for shipping.

How are mailer boxes made?

Mailer boxes are made by taking a sheet of corrugated cardboard and running them through a die-cutting machine. The “Die” is a large block of wood furnished with blades that can best be described as a “cookie cutter” for cardboard. Creating a custom die can be costly, but only has to be done once, and can be reused over and over again. 

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Printing a Mailer box

There are essentially 2 ways to print on corrugated cardboard

Flexography or Digital 

Flexography: Classic print process using flexible (rubber) plates. Flexo is an affordable means of printing corrugated material, but plate costs are determined by size of impression of each colour. Therefore, plates for a large print design in multiple colours can be a sizable investment. Just like the cutting die, the one-time charge can be easily amortized over high volumes and continuous orders. But for smaller quantities, that cost can be discouraging, which is why you must consider simplifying your design, or going to digital.

Digital: Can print eye-catching 4 colour process designs directly onto corrugated material without the need for expensive plates, but the slower process is best-suited to short runs. 

How The Process Works?


Consultation and Design

We initiate a consultation to identify your packaging requirements, taking into consideration the product specifications, target market, and branding requirements. Following this, we create custom designs that meet your specific needs and specifications.


Prototyping & Production

We’ll share drawings and samples of your packaging solutions with you for your review. Tell us everything! Our team will make any requested changes to your project and get started on your order.


Is That a Knock On Your Door?

12 weeks later, your custom packaging is In The Bag and at your door.

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