What are the types of mailing boxes? How to choose the right specifications?
💡 💡 At a Glance
Mailing Box Four Major Types Plus Specification Selection Guide: A Complete Guide to E-commerce Packaging from Folding Boxes to Gift Boxes.
What Is a Mailing Box
A mailing box, also known as a airplane box, postal box, or express delivery box, is a corrugated paper box formed by die-cutting, creasing, and folding. It is mainly used for e-commerce shipping, postal express, and product mailing scenarios. Its core features include one-piece folding, no gluing or minimal adhesive required, flattened for transport to save shipping costs, and quick fold-to-shape assembly when in use.
The difference between a mailing box and an ordinary carton (a shipping box that requires tape sealing) lies in the fact that a mailing box comes with its own opening and closing structure, usually featuring a tuck-in flap or snap-lock, requiring no tape to seal; an ordinary carton, on the other hand, requires tape sealing and has a relatively simple structure.
Type 1: Folding Aircraft Box
This is the most classic mailing box. A single piece of corrugated board is die-cut and creased, then folded into shape, with locking tabs on the top and bottom.
Material: E-flute corrugated (thickness approx. 1.5mm) or B-flute corrugated (thickness approx. 3.0mm). E-flute is suitable for lightweight products under 5kg, while B-flute is suitable for medium-weight products of 10-20kg.
Printing: Typically offset four-color printing, with gloss film or matte film lamination on the surface. The lamination makes it wear-resistant, waterproof, and stain-resistant.
Application: Apparel, small electronic products, cosmetics, books, and food takeout.
Advantages: Folding and shipping saves 70-80% volume, requires no glue, and allows for fast assembly (within 30 seconds).
Type 2: Window Mailing Box
Based on the folded tuck-top box, a transparent window (PET or PVC sheet) is cut into the box surface, allowing consumers or couriers to see the product inside.
Window Size: Typically accounts for 30-50% of the box surface area. The window is usually positioned on the front or top.
Window Material: PET (food-grade, safe for direct food contact) or PVC (low cost, but not environmentally friendly). PET is recommended for food products.
Applications: Food gift boxes, toy packaging, cosmetics, daily necessities.
Advantages: The product can be seen without opening the package, making it suitable for scenarios that require visual confirmation.
Type Three: Sleeve Mailer Box
Composed of two boxes—an outer sleeve and an inner box—formed separately. The inner box holds the product, while the outer sleeve fits over the outside and can be printed with a LOGO or pattern.
Structure: The inner box is typically a folding airplane box, and the outer sleeve is a simple open-and-close slipcase.
Application: Gifts, electronic products, cultural and creative products, and brand-upgrade packaging.
Advantages: The unboxing experience feels ceremonial, and the outer sleeve can be reused for storage.
Disadvantages: The cost is 30–50% higher than a single-layer airplane box, and there are more assembly steps (the inner box must be packed first before sliding on the outer sleeve).
Type Four: Gift Mailer Boxes
This is a high-end category of mailer boxes, typically made from greyboard with face paper or specialty paper, and may feature processes such as hot stamping, embossing, UV, and textured pressing.
Materials: Greyboard (1.5-2.5mm) laminated with specialty paper or 300-350g white card with film lamination.
Processes: Combinations of hot stamping, embossing, spot UV, textured pressing, silk screen printing, etc.
Applications: High-end gift boxes, brand merchandise, holiday gift boxes, customized gift boxes.
Advantages: High-end appearance, suitable for gifting directly.
Disadvantages: Cost is 2-5 times that of ordinary mailer boxes, not suitable for budget e-commerce.
Specification Selection Reference Table
The following provides common mailing box specification references by product type:
Small accessories (data cables, earphones, phone cases): outer dimensions 10-15cm × 10-15cm × 5-8cm, E-flute corrugated recommended.
Medium apparel (T-shirts, shirts): outer dimensions 25-35cm × 20-25cm × 5-10cm, E-flute corrugated recommended.
Shoe box (single): outer dimensions 30-35cm × 18-22cm × 12-15cm, B-flute corrugated recommended.
Medium electronic accessories (small speakers, keyboards): outer dimensions 30-40cm × 25-35cm × 10-15cm, B-flute corrugated recommended.
Cosmetic gift box (medium to large): outer dimensions 25-30cm × 20-25cm × 15-20cm, B-flute corrugated or EB-flute double-wall corrugated recommended.
How Thickness Matches Product Weight
The thickness of a mailer box is not the thicker the better, but should match the product weight and shipping distance.
Lightweight products within 5kg: E-flute corrugated (1.5mm) is sufficient, suitable for clothing, accessories, and books.
Medium-weight products of 5-15kg: B-flute corrugated (3.0mm), suitable for shoe boxes, electronics, and small home appliances.
Heavier products of 15-30kg: EB-flute double corrugated (4.5mm) or BC-flute double corrugated (7.0mm), suitable for home appliances, tools, and fitness equipment.
Heavy-duty products over 30kg: It is recommended to use a standard five-layer corrugated carton with inner lining; the mailer box structure is not recommended.
How to Choose a Printing Process
The printing process for mailer boxes should be selected based on brand positioning and product tier:
Value E-commerce: Offset printing in one or two colors with a glossy film lamination—low cost and short lead time.
Mid-Range Brands: Offset four-color (CMYK) printing with a matte film lamination—excellent color reproduction and a finer texture.
Premium Brands: Offset four-color (CMYK) printing with hot stamping and spot UV—the LOGO and main visuals stand out more.
Digital printing is suitable for small-batch trial sales or custom personalization, with a minimum order quantity as low as 50–100 units, though the unit price is higher.
Summary: Three Dimensions for Selecting a Mailing Box
When selecting a mailing box, start from three dimensions: product type (which determines the box structure), product weight (which determines the corrugated thickness), and brand positioning (which determines the printing process). When these three align, you can select the mailing box solution with the best cost-performance ratio.
FAQ
What is the difference between a mailing box and a mailer box?
A mailing box is the same as a mailer box — these are different names for the same type of packaging. Also called postal box, express delivery box, or folding box. One-piece fold-to-shape construction with top and bottom locking tabs, no tape required.
What materials are used for mailing boxes?
Commonly E-flute corrugated (1.5mm thickness, suitable for up to 5kg) or B-flute corrugated (3.0mm thickness, suitable for 10–20kg). Heavy-duty items use EB-flute or BC-flute double-wall corrugated.
What is the minimum order quantity for mailing boxes?
Standard offset-printed mailing boxes have an MOQ of 500–1,000 units; digital printing can go as low as 50–100 units, suitable for small-batch trial sales or personalized customization.
How to choose the size of a mailing box?
Select based on product dimensions plus 5–10mm buffer space. Small accessories commonly use 10–15cm cubes; medium apparel 25–35cm rectangles; shoe boxes 30–35cm × 18–22cm × 12–15cm.
Do mailing boxes require tape for sealing?
No. Mailing boxes feature built-in locking tabs or snap-lock structures that hold automatically when folded, requiring no tape. This is the key difference between mailing boxes and regular cartons.
Can mailing boxes have a window?
Yes. Window mailing boxes feature a transparent window covering 30–50% of the box face, using PET (food-grade) or PVC material. Suitable for food gift boxes, toys, cosmetics, and other scenarios requiring visual confirmation.
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