Mailer boxes are one of the most popular packaging styles for product shipping and fast delivery. Known for their sturdy structure and ease of assembly, they provide both protection and branding opportunities. When it comes to choosing the right mailer box, the material plays a crucial role in determining durability, appearance, and cost-effectiveness. Below are some of the most common materials used for mailer boxes, along with their characteristics, advantages, and ideal applications.
1. White Cardboard (C1S or Coated White Board)
White cardboard is a dense, smooth-surfaced material that does not shed fibers. The front is typically a bright white surface, while the back is a grey board. One of its main advantages is its ability to produce stable, vivid colors during printing, ensuring that brand logos, images, and graphics appear sharp and consistent.
Another benefit of white cardboard is its resistance to cracking and powdering during folding, which enhances the durability of the mailer box. The smooth surface also offers an excellent base for various finishing techniques such as gloss lamination, matte lamination, or spot UV, allowing brands to further enhance their packaging appeal.
Best for: Premium product packaging, e-commerce shipments requiring brand presentation, and marketing campaigns where print quality is critical.
2. Clay Coated Grey Board (CCNB)
Clay coated grey board, often referred to as “grey board with white surface,” is commonly used for mailer boxes with colorful printed designs. Its surface coating allows for detailed image printing, making it suitable for packaging that needs to be visually appealing.
However, one drawback of CCNB is its lower structural strength compared to other materials. It is more prone to cracking after folding, which may affect the box’s long-term durability. For this reason, manufacturers often apply additional glue treatment to reinforce the structure and extend the box’s usability.
Best for: Lightweight products, promotional packaging, and seasonal campaigns where cost efficiency and colorful printing are priorities.
3. Kraft Cardboard
Kraft cardboard retains its natural brown color, providing an eco-friendly and rustic aesthetic. When paired with minimalist designs and printing, it can create a strong visual impact while aligning with sustainable brand values.
The texture and appearance of kraft cardboard give mailer boxes a premium feel. It is also comfortable to handle, has good water resistance, and offers strong durability against folding and abrasion. This makes kraft cardboard a versatile material for brands that value both environmental responsibility and product protection.
Best for: Eco-conscious brands, artisanal products, subscription boxes, and packaging that prioritizes sustainability and durability.
4. Corrugated Kraft (Brown Corrugated Board)
Corrugated kraft mailer boxes are made from unbleached corrugated board, typically in their natural brown color. These boxes are lightweight yet strong, making them an economical choice for shipping. The corrugated structure offers enhanced protection during transit, helping to prevent damage from impact, compression, or rough handling.
Because of their low cost and strength, corrugated kraft mailer boxes are widely used for e-commerce and bulk shipments. While the printing options may be more limited compared to coated boards, simple branding such as single-color logos or eco-friendly inks can still create a professional and appealing look.
Best for: High-volume shipping, cost-sensitive projects, and products requiring extra protection during transit.
Choosing the Right Material for Your Mailer Boxes
Each material comes with its own strengths and limitations, so the best choice depends on your product type, branding goals, and budget.
For high-end branding: Choose white cardboard for its premium printing quality and smooth finish.
For colorful designs on a budget: Opt for clay coated grey board, but ensure reinforcement for durability.
For sustainable appeal: Kraft cardboard offers both an eco-friendly look and strong performance.
For cost-effective shipping protection: Corrugated kraft provides excellent durability at a lower price point.
When selecting a material, it is important to consider not only the appearance but also the practical aspects of your packaging. Factors such as shipping distance, product fragility, customer experience, and environmental impact should all be part of your decision-making process.
Final Thoughts
Mailer boxes are more than just protective containers—they are an extension of your brand. The right material can enhance your product’s perceived value, protect it during transit, and convey your brand’s message to customers. Whether you’re aiming for a luxurious unboxing experience, eco-friendly presentation, or cost-effective shipping solution, understanding the strengths of each material will help you make the best choice.
At PandaPackage, we specialize in custom mailer box solutions tailored to your brand’s needs. From material selection to printing and finishing, we work closely with you to create packaging that is functional, visually appealing, and aligned with your business goals. Contact us today to explore how we can bring your packaging vision to life.
