Min. 100 units · 3–5 days
E Commerce Boxes
Custom Mailers
Specify thisCustom Mailers
Bespoke corrugated Shipping Boxes manufactured to order, with material and finish chosen around how the product ships.
No obligation
Name, email, phone and what you are packing and how it ships. Attach artwork if you have it. We reply with a specification and a written price, usually within one business day.
The box is crushed from above in a stack rather than damaged in handling, and the failure appears at the bottom of a pallet.
Stack height and how long the stack stands matter more than contents weight when choosing a flute.
Corrugated Shipping Boxes hold heavier or bulkier goods that need to survive stacking as well as handling. That is the starting point for the specification, because stack height and how long the stack stands matter more than contents weight when choosing a flute.
In service they are used for wholesale despatch and pallet freight where boxes are stacked several high for days.
Corrugated Shipping Boxes are specified for wholesale despatch and pallet freight where boxes are stacked several high for days. Stack height and how long the stack stands matter more than contents weight when choosing a flute.
Where a product needs to be held still, a fitted insert cut to its profile does more for damage rates than a heavier outer board. It usually costs less too, because you can drop a grade on the outer.
Single-wall B or C flute for most loads; double-wall where stack height goes past about five high or the contents exceed roughly 20 kg.
The options we would consider for this format are below; stack height and how long the stack stands matter more than contents weight when choosing a flute.
Regular slotted construction from around 8 × 6 × 4 in upward, with no real ceiling before freight becomes the constraint.
Send the contents rather than a box size. Board is specified for the weight of the contents rather than the weight of everything stacked on top, which is what actually decides the flute.
Boxes ship flat and knocked down, stacked on pallets for volume orders.
Delivery windows are confirmed in writing when your order moves into production, and we flag any risk to the date before you approve rather than after.
Four things drive a quote more than anything else: the quantity, the print route, the board grade and the number of finishing passes. Dimensions matter too, but usually through how efficiently the shape nests on the press sheet.
Prices start from $0.30 per piece for large-volume orders. If a cheaper route exists we say so at quoting rather than after the invoice.
The useful starting point is the product, not the pack. Give us its measurements and the quantity, and we work the corrugated box outward from there.
We send a dieline sized to your product, check your artwork and issue a proof. For shipping formats we will also flag it if the pack looks a size larger than it needs to be.
Ask for an unprinted sample if the question is fit, or a printed prototype if the question is colour. They answer different things.
Sample costs are normally credited against the production order.
Reference
| Product | Corrugated Shipping Boxes |
|---|---|
| Category | Custom Mailers |
| Construction | Die-cut or slotted, glued or stitched |
| Board grade | E, B or BC double-wall flute |
| Ships as | Flat, knocked-down on pallets |
| Materials | E-flute corrugated, B-flute corrugated, Double-wall BC-flute, Kraft corrugated |
| Printing | Flexography, Litho-lamination, Digital press |
| Finishes | Flood coating, Matte lamination on litho-laminated panels, Spot UV on litho-laminated panels |
| Minimum order | Minimum order is 100 units on any format, and unit cost falls sharply as the quantity rises. |
| Lead time | 3 to 5 business days after artwork approval |
| Shipping | Across the US, UK, Canada and Australia |
Specification builder
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What you get
Regular slotted construction from around 8 × 6 × 4 in upward, with no real ceiling before freight becomes the constraint.
The box is crushed from above in a stack rather than damaged in handling, and the failure appears at the bottom of a pallet.
Specified for wholesale despatch and pallet freight where boxes are stacked several high for days.
Stack height and how long the stack stands matter more than contents weight when choosing a flute.
This format sits in our custom mailers range, alongside 31 other made-to-order formats.
Answers
Specification, minimums and lead times for corrugated shipping boxes.
Send the stack height and the weight sitting above the bottom box, not just the contents weight. Compression failure comes from the stack, and the same flute can be right or badly wrong depending on it.
That depends on board grade, contents weight and how long the stack stands. Send us the stack height and the weight above the bottom unit and we will specify to it rather than guessing at a grade.
Only if boxes are arriving crushed. If they arrive intact with damaged contents, the product is moving inside and a heavier outer changes nothing. A fitted insert solves that case, usually at lower cost.
Yes, and for corrugated shipping boxes we prefer to specify both together. A cavity that holds the contents still often lets us drop a grade on the outer, so the pair can cost less than an over-specified box alone.
Measure the product rather than the box currently in use. Most operations we quote are running at least one size too large with void fill compensating, and dropping a band saves on every parcel corrugated shipping boxes carry.
That is a brand decision, not a cost or protection one. For direct-to-consumer parcels where the customer opens it, print can be worth it. For business deliveries it usually is not.
Send the current specification or a physical sample and we will quote to match it rather than proposing an alternative you would then have to re-approve internally. A physical sample tells us more than a specification sheet — board caliper and coating are usually described loosely and measured exactly.
All 50 US states, the United Kingdom, Canada and Australia, on the same timeline everywhere: 3 to 5 business days of production after artwork approval, then 5 to 7 business days in transit. Every run is made to order and shipped directly to your address rather than pulled from stock, so you receive current production rather than whatever has been sitting in a warehouse. Freight is costed separately by weight, volume and destination. If you are shipping to a fulfilment centre rather than your own address, send their receiving requirements with the order — pallet height and labelling rules are usually fixed and refusals are expensive.
Every run is cut to your dimensions — there are no stock sizes here. Send the product measurements rather than a box size and we will build the corrugated box around them, then send a dieline template you can design onto.
We issue a dieline template sized to your product, prepress checks your artwork against it, and a proof comes back for sign-off. Nothing runs until you approve that proof, and corrugated boxes then take 3 to 5 business days.
Yes. Once a first run is approved we hold the board, structure, dimensions, print method and finishes against your account, so a reorder references the same specification exactly rather than being re-derived. It also means a reorder can be priced against a larger quantity without re-opening the specification.
Recycled grades are available across most of the substrates we run for corrugated boxes. Recycled content, kerbside recyclability and certified compostability are three different claims though, so tell us which one you intend to print.
Related formats
Next step
Send the dimensions, the quantity and how it ships. We reply with a full specification and a written price, usually within one business day.