Luxury Mailer Boxes.

The outside is a printed sheet laminated onto E-flute, where a standard mailer has ink applied straight to the liner. Litho lamination gives you photographic print on a box that still has a structural corrugated core. The flute takes care of protection while the laminated face handles presentation.

That combination lets one box replace the usual pairing of a plain shipper and a separate gift box, which also removes a packing step and the outer carton's freight.

Soft-touch film is the finish that marks most in transit, which is the reverse of what most people expect from a premium coating. Its velvety surface picks up rub marks from conveyor belts, chutes and other parcels, and black soft-touch shows every one. On these builds we add an anti-scuff additive to the laminate.

The additive narrows the gap between hand feel and arrival condition. It doesn't close it completely, so we run the actual laminate through real transit before production.

Move to B-flute once the contents are heavy enough that E-flute walls bow or the corners crush in a drop test. E-flute is our standard here because it takes litho lamination cleanly and holds a crisp edge. B-flute cushions better and stacks stronger, though the thicker wall can show a little more fluting under the laminate.

A fitted insert often solves the problem first. Holding the contents off the walls means the board isn't absorbing every knock.

Yes, foil works on corrugated when the box is litho-laminated, because the foil goes onto the printed sheet before it is mounted to the flute. Stamping directly onto a corrugated liner tends to crush the flutes and leave a patchy mark. On the laminated sheet the foil sits flat and sharp.

Matte or gloss lamination, soft-touch with anti-scuff and a full interior flood print are the other usual choices. Most of our premium builds pair a quiet exterior with a strong colour inside.

It holds everything in a set position so the contents present when the lid opens, instead of sliding into one corner on the way. A die-cut insert in paperboard or corrugated is shaped around the items and decides the order the customer sees them in. It also keeps a glass bottle or a boxed item away from the side walls.

We draw the insert alongside the box dieline, so the fit gets checked on the sample before bulk.

Our most common premium builds are 10 × 8 × 3 in and 12 × 9 × 4 in, measured as internal length by width by depth. Every box is cut to size, though, so start from the product and any insert rather than from a stock dimension. Laminated board adds a little thickness to each wall, and we allow for it on the dieline.

Send the item dimensions with the insert you have in mind and we'll draw it up. Design help costs nothing.

Our minimum for this build is 500 boxes, and a single order can go as high as 100,000. Litho lamination involves a printed top sheet, a mounting step and a cutting die, so very short runs don't make sense on this format. At 500 the setup spreads across enough boxes to stay reasonable.

Keep the dieline the same between reorders and the die is already made next time. Only the print changes if you refresh the artwork.

Yes, and on a soft-touch box we'd push you to do exactly that before committing. A physical sample takes 5 to 7 business days to make. Production then runs 7 to 10 business days once you approve the proof, and a rush order can be done in 5 to 7.

The sample fee comes off the production invoice when you go ahead, so testing the real laminate costs you nothing extra in the end.