Roll-End Tuck Top Boxes.

The side walls roll up with an attached flap folding over inside, so each wall is doubled. That gives far more crush resistance than a single thickness of corrugated would suggest, without buying heavier board. The dust flaps double the corners too, which is where crush damage usually starts.

E flute is the standard for this mailer, and we move to B flute for heavier or more fragile contents.

No, it locks together with folds alone. The lid wings slot down into the doubled side walls and the front panel tucks in, so there's no glue line and no tape. The customer opens it without a knife, which is a big part of why this became the standard e-commerce mailer.

For extra security in the post, an ear lock or a tear strip can be added, and the tear strip gives a clean first opening.

Yes, and the inside of this style is an unusually good surface for it. Because the walls are doubled, the interior faces come up clean and flat when the lid opens. A pattern, a thank-you line or a logo under the lid is the part of the box people tend to photograph.

Interior print is a second print side, so ask for it at quote stage and we'll price it with the outside.

Litho-laminated board gives photographic print and takes foil, spot UV, embossing and matte, gloss or soft-touch lamination. Those finishes sit on the printed sheet bonded over the flute, so they behave much as they would on a folding carton.

Flexo on natural kraft is the economical route for logos and line work, kept to one or two ink colours. A laminated face resists scuffing in the parcel network better than bare ink does.

Common builds are 8 × 6 × 2 in and 12 × 9 × 4 in, and every size is cut to order. We size from the inside dimensions of what goes in, plus any insert or tissue.

Right-sizing matters on this style because parcel carriers charge on dimensional weight. A mailer that fits closely costs less to send, needs less void fill and lets the contents move less in transit.

Yes, the whole box is corrugated fibre and goes out with standard cardboard recycling. Recycled fluting with high recycled content is available, and since there's no tape or glue to peel off, the customer just flattens it.

Plastic lamination on a litho face is the exception, because it adds a film layer. If recyclability is printed on the mailer, we'd use an aqueous coat or print flexo on kraft.

Mailer orders start at 500 boxes per size. Plenty of online shops take one size at the minimum first, then add a second once they know which products ship together. Larger programmes go up to 100,000.

The unit cost falls as the quantity rises, so it's worth asking us to quote two or three quantities side by side.

Mailers come out of production 7 to 10 business days after proof approval. A rush order takes 5 to 7 business days.

We'd send a sample first, which takes 5 to 7 business days, and test the front tuck with the box filled and handled the way a courier would. The amount you pay for that sample is credited against the full run.