Kraft Mailer Boxes with Inserts Cut Around Your Kit
When a box holds more than one thing, an insert stops the items sliding into each other on the way to your customer. We cut the mailer and the insert together, so the cavities line up with what you send.
Written price from£0.25 a box
What are kraft mailer boxes with inserts?
Kraft mailer boxes with inserts are brown fold-over mailers that come with a card or corrugated insert holding each item in its own cut-out. They suit skincare sets, gadgets, subscription kits and anything with glass inside. Both parts are delivered flat.
- Box
- Roll-end mailer with a tuck-front lid and dust flaps
- Insert
- Card or corrugated, with cut-outs shaped to each item
- Outside, inside the lid, or both
- Arrives
- Mailers and inserts flat, packed together
Kraft Mailer Boxes with Inserts Sizes
| Size | Typical inside size | Fits |
|---|---|---|
| Small kit | 180 × 130 × 50 mm | Skincare set |
| Medium kit | 250 × 180 × 70 mm | Gadget, bottles |
| Large kit | 310 × 230 × 90 mm | Gift set |
| Deep | 250 × 200 × 120 mm | Jars, candles |
Sizes are typical starting points, not stock sizes. Every box is cut to the inside size you send.
Who needs a mailer with an insert?
Anyone posting a set rather than a single item. Skincare brands send a cleanser, serum and balm together. Coffee roasters send a bag of beans with a grinder. Tech sellers send a device, a cable and a charger in one parcel.
Without an insert, those items rattle and rub. The customer opens a box where everything has slid to one corner. With an insert, they open a box where each piece sits exactly where you put it.
These sit in our kraft inserts and dividers range, alongside bottle packs and box dividers.
How does the insert sit inside the mailer?
The insert is a separate piece cut to the inside of the mailer. It drops in flat, or folds into a raised platform, and its cut-outs hold each item.
Our photos show several approaches. One has a single rectangular well for a boxed product. Another has a deep layered insert with shaped cavities for a set of small parts. A third is a lid-and-tray kit where the insert divides the base into compartments.
- Flat insert with simple cut-outs for flat items such as cards and pouches
- Raised platform insert that lifts short products to the lid line
- Layered insert with shaped cavities for awkward items
- Compartment insert with walls for jars and bottles
Card insert or corrugated insert?
Both come in brown kraft and both can be cut to shape. The choice depends on what the insert has to do.
Card is thinner and gives sharp, clean cut-outs. Corrugated is thicker and gives deeper cavities and more cushioning around glass.
| Insert | Looks like | Choose it for |
|---|---|---|
| Brown kraft card | Thin, smooth, crisp edges | Skincare tubes, cards, light accessories |
| Brown kraft corrugated | Thicker, with a visible fluted edge | Glass jars, bottles, devices |
| Layered corrugated | Several sheets glued into a deep block | Shaped items that must not move |
| White-lined card | Pale top face, brown underside | Bright print on the insert, on request |
If you are unsure, tell us what the items are and how they travel. We suggest the insert when we quote, and the proof shows how deep each cavity will be.
How do you size the mailer and insert together?
Start with the items, not the box. Lay them out in the order you want the customer to see them, leaving a little board between each one. Measure the length and width of that layout and the height of the tallest piece.
Send us those numbers, plus each item's own size. We work out the cavities, then set the mailer around the insert.
Common starting points are a small kit at about 180 × 130 × 50 mm, a medium kit at about 250 × 180 × 70 mm, a large kit at about 310 × 230 × 90 mm and a deep version at about 250 × 200 × 120 mm for jars and candles. They are guidance only.
Does the inside of the lid need printing?
It is worth thinking about. The inside lid is the first thing a customer sees when the mailer opens, and on a kit it sits right above the insert.
One photo shows a deep green inside print behind a cut-out insert, another a short message and a set of icons. Even one colour on the inside lid makes the opening feel planned.
The outside can stay plain brown with a small logo, or carry a full design. If you want to see the logo placement first, place your logo in Design Your Box and send it with your request.
Can the insert itself carry print?
Yes. A printed insert can label each cavity, show a numbered order of use, or carry a short thank-you around the edge. Brown kraft card takes black ink cleanly, and white-lined card is available on request for full colour.
Keep print away from the cut-out edges. A line of text that runs into a cavity looks broken once the product sits in it.
What goes wrong with kit inserts?
- Cavities are cut to the product's listed size, but the real item is a few millimetres larger.
- A pump or dropper cap is measured closed, then sent with the cap off, so it no longer fits.
- The insert is the full depth of the mailer and the lid will not close over the tallest item.
- Finger notches are missed, so customers struggle to lift a snug item out.
- Items are reformulated or resized and the old inserts no longer match.
The fix for most of these is a sample of each item with us before the insert is cut. If that is not possible, a photo of each item beside a ruler is the next best thing.
Packing and posting a kit
Fold the mailer, drop the insert in, then place the items in their cavities in the same order each time. A printed layout card on the packing bench saves mistakes when several people pack.
The tuck-front lid closes without tape, but most sellers add a sticker or a strip of paper tape for the post. For very fragile kits, put the whole mailer inside a plain outer box.
Because both parts arrive flat, a busy month's stock fits on a few shelves rather than filling a stockroom.
Subscription boxes and launch kits
Subscription sellers often keep the mailer the same every month and change only the insert. A standard outer with a new insert for each month's items is easier to manage than a new box every time.
Launch kits for press and influencers are the opposite. They are short runs where the inside print and a tight insert carry most of the impression.
For both, think about the order the customer meets each item. Put the hero product in the centre cavity, with smaller extras around it.
How do I order kraft mailers with inserts?
Send the list of items with their sizes, a photo of the layout you want, the quantity and your print choices for the mailer and the insert.
A written quote comes back, with prices from £0.25 per unit depending on size, insert and print. Our designers set the artwork on both dielines and send a free proof, edited until you are happy.
We start production after you approve and finish in 4–6 business days. UK tracked delivery is free and arrives in 2–3 business days. A faulty mailer or insert, whether misprinted, mis-sized or dented in transit, earns a reprint or refund when your photos reach us inside 10 days.
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Questions About Kraft Mailer Boxes with Inserts
Straight answers from the people who cut and print the boxes. Open any question to read the reply.
Can you cut an insert to fit my exact products?
Yes. Each cavity is cut to the item you send. Send each item's size, or better, a sample, so the fit is snug.
Is the insert glued into the mailer?
No. The insert is a separate piece that drops into the mailer. That lets you swap inserts while keeping the same outer.
Can one mailer take different inserts for different kits?
Yes. Many subscription sellers keep one outer size and order a new insert each time the contents change.
Will a corrugated insert protect glass jars in the post?
A corrugated insert keeps jars apart so they do not knock together. For very fragile glass, we suggest an outer shipping box as well.
Can I have a finger notch to lift items out?
Yes. A small half-moon cut beside a cavity lets customers lift a snug item without tipping the box.
Can the insert be printed?
Yes. Brown card prints well in black ink. White-lined card is available on request if you want full colour on the insert.
Do inserts arrive folded into shape?
No. Inserts and mailers both arrive flat. Simple flat inserts drop straight in; raised inserts fold up in a few seconds.
Can a mailer with an insert be printed inside?
Yes. Inside print on the lid is popular because it sits right above the kit when the box opens.
What if my product sizes change later?
Send the new sizes and we cut a new insert. The mailer often stays the same, which keeps your artwork and proof simple.
Can you make an insert with a raised platform?
Yes. A platform lifts short items up to the lid line so the box looks full when opened.
Do I need to send samples of my products?
It helps for tight inserts, but it is not required. A photo of each item beside a ruler and its measured size will do for most kits.
Will I see the insert layout on my proof?
Yes. The proof shows the mailer and insert dielines with each cavity marked, so you can check the layout before production.
Tell us what you ship
Send the product, a rough size and a quantity. We reply in writing within one business day with a price and a free design proof. Prefer to talk? Call +44 7578 382054 or message us on WhatsApp.