Custom Mailers

Corrugated Shipping Boxes

Bespoke corrugated Shipping Boxes manufactured to order, with material and finish chosen around how the product ships.

Minimum order
100 units
Production
3–5 business days
Construction
corrugated box
Delivery
US, UK, Canada, Australia

No obligation

Price this format

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 more detail you give, the more accurate the quote.

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    How corrugated shipping boxes fail, and what prevents it

    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.

    What corrugated shipping boxes have to cope with

    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.

    Where corrugated shipping boxes are actually used

    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.

    • Wholesale despatch and pallet freight where boxes are stacked several high for days
    • E-commerce shipping
    • Wholesale and distribution
    • Retail-ready shelf cases

    Holding the contents in place

    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.

    • Corrugated insert
    • Tear strip
    • Double-wall upgrade
    • Handle cut-out

    The substrate for corrugated shipping boxes

    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.

    • E-flute corrugated
    • B-flute corrugated
    • Double-wall BC-flute
    • Kraft corrugated
    • White-top corrugated

    Sizing corrugated shipping boxes

    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.

    Getting them to you, and onward

    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.

    What moves the price

    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.

    Ordering corrugated shipping boxes

    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.

    Testing the fit first

    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

    Corrugated Shipping Boxes at a specification level

    ProductCorrugated Shipping Boxes
    CategoryCustom Mailers
    ConstructionDie-cut or slotted, glued or stitched
    Board gradeE, B or BC double-wall flute
    Ships asFlat, knocked-down on pallets
    MaterialsE-flute corrugated, B-flute corrugated, Double-wall BC-flute, Kraft corrugated
    PrintingFlexography, Litho-lamination, Digital press
    FinishesFlood coating, Matte lamination on litho-laminated panels, Spot UV on litho-laminated panels
    Minimum orderMinimum order is 100 units on any format, and unit cost falls sharply as the quantity rises.
    Lead time3 to 5 business days after artwork approval
    ShippingAcross the US, UK, Canada and Australia

    Specification builder

    Specify Corrugated Shipping Boxes in under a minute

    Set what you know, leave the rest. Everything here travels with your request, so nothing gets retyped.

    • 100-unit minimum
    • 3–5 day production
    • Free dieline
    • No obligation
    Approximation only — proportions, colour family and finish character. Not a colour proof, and the panel shown is a placeholder, not your artwork.
    Packaging type
    Box style
    Quantity
    Colour
    Material
    Printing
    Finish

    Drop files or browse

    Up to 5 files, 10 MB each.

      Prices start from $0.30 per piece for large-volume orders. Final pricing depends on size, material, printing, finishes, and quantity.

      What you get

      Where the construction earns its cost

      Dimensions and clearance

      Regular slotted construction from around 8 × 6 × 4 in upward, with no real ceiling before freight becomes the constraint.

      What goes wrong in transit

      The box is crushed from above in a stack rather than damaged in handling, and the failure appears at the bottom of a pallet.

      Where it has to work

      Specified for wholesale despatch and pallet freight where boxes are stacked several high for days.

      What decides the job

      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

      Ordering corrugated shipping boxes: the usual questions

      Specification, minimums and lead times for corrugated shipping boxes.

      What flute grade do I need?

      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.

      How high can these be stacked?

      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.

      Will a heavier board reduce my damage rate?

      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.

      Do you supply inserts with the outer?

      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.

      How do I reduce dimensional weight?

      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.

      Should the outside be printed?

      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.

      Can you match packaging we already use?

      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.

      Where do you deliver?

      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.

      Can I order corrugated shipping boxes in a custom size?

      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.

      What happens after I approve the quote?

      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.

      Can you hold the specification for repeat orders?

      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.

      Do you offer recycled or recyclable options?

      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.

      Next step

      Start on Corrugated Shipping Boxes

      Send the dimensions, the quantity and how it ships. We reply with a full specification and a written price, usually within one business day.