Overview & Specifications
What Are Corrugated Mailers?
Corrugated mailers are one-piece mailer boxes made from corrugated board: a fluted middle layer glued between two flat liners. The flutes add thickness and edge structure compared with single-ply paperboard. Packaging Dock builds them on the Roll End Tuck Top structure, so they ship flat, fold into shape at packing and close with a tuck-top lid.
They are part of the Mailer Boxes range. This page focuses on selecting fluted board for the current Roll End Tuck Top product; the other mailer structures are separate products.
How Board, Flute and Liner Work Together
The material and the box are separate decisions: the corrugated board sets wall thickness and the print surface, while the Roll End Tuck Top cut and fold sets how the box opens. Start with the packed load and dimensions, then choose board grade, flute and liner together; flute thickness alone gives an incomplete picture of the finished mailer.
01
Board grade
contributes to performance under the packed load.
02
Flute
sets wall thickness, which changes usable inside space.
03
Liner
the printing surface; it shapes the print result.
What it has to do
What a Corrugated Mailer Has to Do
A corrugated mailer specification connects board grade and flute with packed weight, panel size, liner printing, product fit and assembly.
01
Match
Match the Flute to the Load
Board grade, flute, dimensions and packed weight can be matched to the application instead of assuming one universal strength level. Assess E- and B-flute against the packed configuration; board grade and support design remain part of that decision.02
Add
Add Edge and Panel Structure
The corrugated medium adds thickness and edge structure compared with single-ply paperboard, and the rolled side walls double the board along each side.03
Take
Take Print on the Liner
Exterior printing can support clear shipping and brand communication, while compatible interior printing can shape the opening experience. Print method is selected for the liner surface.04
Fit
Fit the Product Closely
Mailer dimensions can be developed around the product, cushioning and any required insert or partition. A planned interior reduces unnecessary movement and creates a consistent position for products during packing.05
Fold
Fold Up Fast at Packing
The one-piece blank ships flat and is assembled before loading. The lid tucks shut; supplemental sealing, tear strips and adhesive strips are selected for the project and route.
The Mailer Construction Used Here
Corrugated mailers here are Roll End Tuck Top Boxes cut from fluted board, with rolled walls and a tuck-top lid. The board defines the material; the dieline defines how the mailer forms and closes. Review folded wall thickness and liner orientation before approving artwork.
Corrugated board is also offered on the separate Roll End Tuck Front, Roll End Boxes with Lid and Roll End 3 Flap Lock products.
Corrugated Mailers vs Related Mailer Pages
These pages share the Roll End Tuck Top build; choose by the main decision. Corrugated Mailers covers board grade, flute and liner; Shipping Mailer covers the complete packed system; FSC Corrugated covers certified fiber sourcing; Tuck Top covers the structure itself.
| Page | Main decision | Choose When |
|---|---|---|
| Corrugated Mailers | Board grade, flute and liner | A fluted-board material requirement |
| Custom Shipping Mailer Boxes | Cushioning, sealing and distribution | A complete shipment specification |
| FSC Corrugated Mailer Boxes | Documented certified fiber sourcing | A sourcing requirement |
| Roll End Tuck Top Boxes | Folding and closing geometry | The underlying structure |
E-Flute vs B-Flute Corrugated Mailers
E-flute has a finer flute profile; B-flute has a larger flute profile. Compare the proposed board grade, liners, printing process and finished box together. Thickness alone establishes neither a strength rating nor a shipping guarantee.
| Factor | E-Flute | B-Flute |
|---|---|---|
| Profile | Finer flute | Larger flute |
| Typical thickness (reference) | About 1.1–1.6 mm | About 2.5–3.2 mm |
| Fit review | Folded walls and insert clearance | Greater folded-wall bulk and insert clearance |
| Printing review | Liner, artwork and print method | Liner, artwork and print method |
| Performance review | Complete packed configuration | Complete packed configuration |
Thickness figures are general reference values, not ratings. Solid paperboard is a separate material choice for suitable presentation builds; the product on this page uses fluted board.
Corrugated Mailer Specifications
Corrugated mailers are specified around board grade, flute, dimensions, inserts and liner print method. Review the specifications below to plan the board, box and production.
| Specification | Available Configuration |
|---|---|
| Product Type | Corrugated Roll End Tuck Top mailer |
| Category | Mailer Boxes |
| Construction | Roll End Tuck Top mailer: one-piece die-cut blank, rolled double-layer walls, attached tuck-top lid |
| Dimensions | Customized around packed product and insert |
| Board | E-flute or B-flute corrugated; board grade and liner specified around the complete packed load |
| Interior | Inserts, partitions or cushioning where required |
| Inserts | Paperboard, corrugated, foam/EVA or molded pulp; thermoformed PET/PVC trays also offered for mailers |
| Ecommerce Features | Tear strip, adhesive strip, tongue lock, pocket or card slot, where specified |
| Print Coverage | Exterior only, exterior plus inside lid, or broader inside/outside coverage where the board and print method support it |
| Print Methods | Offset, digital, UV, screen or flexographic printing; CMYK and Pantone spot colors |
| Finishes | Matte, gloss or soft-touch lamination, aqueous coating, foil stamping, emboss/deboss, Spot UV and raised 3D UV, according to the board |
| Starting Price | From $1.45 / unit; final price depends on size, board, print coverage, inserts, finishes and quantity |
| Minimum Order | 500 units |
| Standard Production | 7 days from approved proof |
| Rush Production | Available on request |
| Shipping | Ships flat, USA and worldwide |
What Size Corrugated Mailer Do I Need?
Size the mailer from the product or insert outward, then let the board thickness add to the outside. Corrugated walls are thicker than paperboard, so folded wall thickness needs to be included when developing the outside dimensions.
| Input | What to Record |
|---|---|
| Product arrangement | Items, orientations and any retail packaging |
| Interior components | Insert footprint, partitions, cushioning and presentation layers |
| Complete load | Packed weight and contents |
| Final fit | Inside dimensions, and closed outside dimensions for shipping |
| Measurement | Include |
|---|---|
| Product or inner pack | Full dimensions, closures and intended orientation |
| Interior arrangement | Inserts, partitions, cushioning and presentation layers |
| Complete shipment | Packed weight and units per box |
| Final box | Inside fit and closed outside dimensions |
Confirm the finished fit on the approved dieline and a loaded sample where required. Board-by-board inside and outside allowances are on the Roll End Tuck Top sizing guide.
Review the Selected Board as a Finished Box
Assemble the chosen board, load the real product and close the package. Check score lines, folded-wall bulk, insert fit and print appearance on the actual liner. Compare different boards as complete loaded packages.
What to Check Before Bulk Production
Trial the chosen board with the real product and planned packing method. Record the chosen board grade, flute, liner and insert on the approved sample.
| If the trial shows | Review before approval |
|---|---|
| Walls resist assembly | Review scores, folded bulk and insert clearance in the selected board |
| Print differs from the proof | Review artwork on the actual liner and print process |
| Loaded panels distort | Reassess board grade, support and packed layout |
The stated seven days covers standard production from approved proof once the specification is confirmed. Confirm dispatch and delivery timing for the destination separately.
