Kraft Mailer Boxes Cut to the Size of Your Order
A brown corrugated mailer with a hinged lid that tucks in at the front and folds up from one flat sheet. Send us the size of what you post and we cut the box around it, plain or with your logo.
Written price from£0.25 a box
What are kraft mailer boxes?
Kraft mailer boxes are one-piece corrugated boxes with a hinged lid that tucks into the front wall. They fold up from flat without glue or much tape and are made for posting orders, kits and gifts. We cut each one to the inside size you give us.
- Closure
- Roll-end front tuck with two dust flaps that lock the side walls
- Board
- Brown kraft corrugated; white-lined kraft available on request
- Arrives
- Delivered flat, folded by hand in a few seconds
- Plain kraft as standard; one colour, two colours or full colour as options
Kraft Mailer Boxes Sizes
| Size | Typical inside size | Fits |
|---|---|---|
| Small | 160 × 120 × 50 mm | Jewellery, cosmetics |
| Medium | 250 × 180 × 80 mm | T-shirt, candle |
| Large | 310 × 230 × 100 mm | Hoodie, gift set |
| Extra large | 400 × 300 × 150 mm | Bundles, hampers |
Sizes are typical starting points, not stock sizes. Every box is cut to the inside size you send.
Who uses plain kraft mailer boxes?
Anyone who posts small orders and wants the parcel to look tidy when it lands on a doormat. Candle studios, tea sellers, jewellery makers and subscription kits all reach for the same shape.
The box is its own outer carton. It does not need a second box around it for most trips, so one mailer replaces a box, a bag and a roll of tape.
The photos show it plain: brown corrugated, no ink, a clean fold along each edge. Many customers start this way and add a printed logo once they know their sizes.
Plain brown also suits sellers who change products often. One stock of mailers can carry this month's candle and next month's soap, with a sticker or rubber stamp doing the branding.
If your first order needs ink from day one, see our printed kraft mailer boxes with logos instead.
How does the lid of a kraft mailer close?
The lid is hinged along the back wall. As it comes down, a long tongue on its front edge slides inside the front wall and sits there under light tension.
Before that, two small dust flaps on the lid fold over the top of each side wall. They stop the walls bowing outward and keep dust out of the corners.
The side walls are double thickness. Each one folds over itself and locks into slots in the base, which is why the box stands square without glue.
- Tuck-in front: opens and closes again without tearing
- Double side walls: stiff corners that keep their shape in transit
- Dust flaps: cover the gaps where the lid meets the walls
- No glue in the fold: the box goes flat again if you need to store it
How big should my kraft mailer be?
Measure your product, or the stack of items in one order, then add room for any tissue or filler. We cut the inside of the box to the numbers you send, in millimetres.
Our four typical sizes below are only guidance. They are common starting points we see often, not sizes waiting on a shelf.
| Typical size | Inside L × W × H (mm) | What often fits |
|---|---|---|
| Small | About 160 × 120 × 50 | A candle tin, a bar of soap and a card, a pair of earrings on a backing card |
| Medium | About 250 × 180 × 80 | A folded T-shirt, a pouch of tea with a mug, a small skincare set |
| Large | About 310 × 230 × 100 | Two jars with tissue, a hoodie, a boxed set of notebooks |
| Extra large | About 400 × 300 × 150 | A blanket, several products in one order, a bulky gift |
Leave around 5 mm on each side for a rigid item and less for something soft. Our guide on measuring kraft boxes from the inside shows where to put the tape.
Which kraft board suits a mailer?
Mailers are made in brown kraft corrugated. The fluted middle layer gives the walls their spring, so a corner knocked on the way does not crease straight through.
The outside is brown kraft paper, and so is the inside unless you ask otherwise. White-lined kraft, which shows white inside the lid, is available on request.
Other corrugated grades can be supplied on request. Describe the contents and the journey, and our written quote names the board we would use.
Kraft paper is brown right through, so a scuff or a scrape on the way rarely shows as a white mark. That is a quiet advantage for a box that gets handled by several people before it reaches the customer.
Can I print on a kraft mailer later?
Yes. The same dieline works plain or printed, so you can switch when you are ready without changing the size.
Black ink gives the sharpest logo on brown corrugated. White ink makes a softer, lighter mark, and full colour prints a shade warmer than it would on white board.
Inside print is popular on mailers because the lid opens like a page. A short message under the lid costs less ink than covering the outside.
You can try a logo on a real photo first using Design Your Box with your logo.
Can a kraft mailer hold an insert?
Card or corrugated inserts can be added to a mailer. They hold a jar, a bottle or a set of small items in fixed places so nothing slides into a corner.
Inserts change the inside height you need, so mention one when you ask for a price. We size the box and the insert together on the same dieline.
Does a plain mailer look finished without print?
It can. Brown corrugated has a warm, honest look, and many small brands keep it bare on purpose. The clean edges and square corners do most of the work.
Simple touches lift it further. A round sticker on the front tuck, a paper band, a stamped logo or a handwritten name all sit well on brown board.
If you later move to print, nothing else changes. Your size, your packing routine and your shelf space all stay the same.
How do you pack an order into a mailer?
- Fold the base and the two side walls up, then push the wall tabs into the base slots.
- Lay tissue or filler in the bottom if the item is fragile.
- Place the product in the centre and add a card or leaflet on top.
- Fold the dust flaps over the side walls.
- Bring the lid down and slide the front tongue inside the front wall.
- Add a label on the lid and a strip of tape across the front if you want a tamper sign.
Packing many at once is quicker if you fold a stack of bases first, then fill and close them in a line.
What mistakes should I avoid with mailer sizes?
The most common one is measuring the product but not the extras. Tissue, a thank-you card and a sample sachet can add 10 mm of height.
- Sending outside sizes when we ask for inside sizes
- Forgetting that a lid tongue takes up a little room at the front
- Choosing a box much deeper than the item, which lets it rattle
- Picking one size for every product when two sizes would pack tighter
If one mailer has to carry several product lines, our guide on choosing a kraft box for your product helps you narrow it down.
How are kraft mailers delivered to you?
Every mailer arrives flat and stacked in bundles. That keeps your shelf space small until the day you pack.
The cartons travel to you on free tracked delivery, landing at your UK address 2–3 business days after they leave production.
Our page on free tracked UK delivery explains timings and tracking.
How do I order kraft mailer boxes?
Tell us the inside length, width and height, how many you want priced and whether the box stays plain. A phone photo of the product next to a ruler lets us check the fit before we quote.
Plain mailers start from £0.25 per box, and every figure is set out for you in a written quote. Quantities are quoted per order, so feel free to ask for two or three price points side by side.
Your design proof is free, and edits are unlimited. Once it is approved we make the mailers in 4–6 business days.
Should any mailer turn up damaged, misprinted or cut to the wrong size, send us photos inside 10 days. We will reprint the boxes or give you a refund.
Ready for numbers? Ask for a written kraft mailer quote and we reply within one business day.
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Questions About Kraft Mailer Boxes
Straight answers from the people who cut and print the boxes. Open any question to read the reply.
Do kraft mailer boxes need tape to stay shut?
No. The front tongue tucks inside the front wall and holds the lid closed. Many sellers still add one strip of tape or a sticker so the parcel shows if it has been opened.
Can a kraft mailer be posted without an outer box?
Yes, for most small orders the mailer is the outer carton. Put the address label on the lid and keep the item from moving inside with tissue or an insert.
Can you make a slim kraft mailer for small flat items?
Yes. Send the size of the item and we cut a low mailer close to it, then show the final depth on your proof.
Can I reuse a kraft mailer for returns?
The tuck lid opens without tearing, so customers can send items back in the same box with a fresh label and a strip of tape.
What colour is the inside of a plain kraft mailer?
Brown, the same as the outside. For a white inside, ask for white-lined kraft on request.
Do you make kraft mailers without a front tuck?
Yes. A mailer with a tear strip and a self-seal flap is an option for sellers who want a one-time opening.
Can I order kraft mailers in two sizes at once?
Yes. List both inside sizes on your request and we price each one on the same written quote.
How many kraft mailers come in a bundle?
It depends on the size of the box. Your written quote shows how the order is packed so you can plan shelf space.
Can I put my logo on just the lid of a mailer?
Yes. A single one-colour logo on the lid is the simplest printed option, and we place it on the dieline for you at no charge.
Are kraft mailers stiff enough for glass jars?
Brown kraft corrugated gives good corner protection, and a card or corrugated insert stops jars touching. Send a photo of the jars and we will suggest a layout.
Do kraft mailers come with dust flaps on every size?
Yes, the standard design has dust flaps on the lid at each side. Very shallow mailers may use smaller flaps, which we show on the proof.
Can you match a mailer to an existing box I use?
Send us the inside size of the box you use now, or a photo with a tape measure, and we cut the new mailer to match it.
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.