Choosing The Right Packaging Between A Mailer Box And A Shipping Box

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Emilly August 22, 2025

Ever considered how a simple choice between a mailing box and a shipping box could impact your e-commerce business? E-commerce is growing every year. Knowing the difference is important to improve customer service and shipping performance. We will discuss the relevant differences between a mailing or shipping box. You can see how choosing the right box can affect price, environmental impacts, and your brand.

Fast fact: 82% of shoppers are willing to spend more on green packaging, so when you choose the right box, you can seize market share.

Choosing the correct shipping package is more than just getting a product from point A to point B; it's about how well the products arrive. Shipping boxes are meant to handle rigidity for heavier items almost always, and mailing boxes can save money and have more potential to be environmentally friendly. Understanding these differences can help refine your own shipping and attract customers back.

Boxes are something every small or big business uses. When creating your brand, you know how crucial it is to create a unique brand. Eco-friendly corrugated cardboard shipping boxes allow you to enhance the customer experience.

Custom packaging is the ultimate way to provide the best unboxing experience. Also, while being eco-friendly packaging that is also recyclable, it is environmentally friendly too.

Customization is the best option to alleviate the already normality of the products on the market and to add value. We have a plethora of packaging options based on product; we have options that are perfect for subscription and display, too.

Elevate your brand with the power of customization and create packaging that suits your product. Choose the right packaging.

Difference Between Mailer Boxes and Shipping Boxes

If you’re considering mailer boxes, there are a variety of types of mailer packaging. You can have a look at the options and see what the right packaging solution is for you, and especially for small items.

What Are Mailer Boxes?

Shipping envelopes or flat mailers, as they are often named, are envelopes that usually have a self-sealing strip. These shipping envelopes come in several styles, thicknesses, and materials, such as poly mailers, bubble mailers, padded paper mailers, flat paper mailers, thick rigid mailers, and many others.

Standard Mailers Boxes

These are your standard custom boxes for mailing products. They work great for documents, photographs, and clothing.

Bubble Mailer Envelopes

These envelopes are lined with bubble wrap as an extra layer of protection. These envelopes are great for fragile goods like electronics and cosmetics.

Kraft Mailer Boxes

If you want an eco-friendly look, consider these Kraft mailer boxes.

Colored Mailer Boxes

Grab these colored mailer boxes instead. If you want to stand out.

Poly Mailer Bags

These boxes are a good option for lightweight, water-resistant boxes that can be used for clothing and other soft items.

Summary of Mailer Types and Specifications
Mailer Type Description Typical Dimensions Typical Materials Weight Range

Flat Mailer

Flat, envelope-like packaging for brochures and catalogs

6" x 9" to 9" x 12"

C1S, C2S

Under 1 ounce

Poly Mailer

Plastic package for small items

Variable (depends on item)

Plastic (various types)

Varies with item and padding

Bubble Mailer

Padded package for fragile items

6" x 9", 9" x 12", 12" x 15" (common)

Bubble wrap, paperboard

Varies with item and padding

Self-Mailer Postcard

Postcard used as a direct mail package

Standard size (4.25" x 6")

C1S, C2S

Under 1 ounce

Small Mailer Box

Small, lightweight box for packaging lightweight items

6.9" L × 16.9" W × 11.8" H

Corrugated cardboard

Up to 2.37 ounces

 

Why To Pick Mailer Boxes

Whether you are an e-commerce business, a retail business, or an event promoter, creating a lasting impression on a limited budget is an essential requirement. But how can you do this? The answer is custom mailer boxes to ship your products and keep your brand visible. Custom mailer boxes provide protection for your products as well as presentation.

Custom mailer boxes can capture your customers' attention and make them fall in love with your brand. Mailers are precise sizes and securely closed, so that the product in the box won't get any damage.

Easy To Assemble

Mailer boxes are easy to assemble and are easy to use for storing items. When you need to take an item out of boxes and into the packaging, take them out, open them up, and pop them open.

Eco-Friendly

Mailer boxes are eco-friendly because they do not come from plastic, and the materials do not create carbon footprints. The materials are all biodegradable, which creates natural land waste. They are also recyclable and reusable.

Self-Locking

These mailer boxes have interlocking flaps. Unlike typical shipping boxes, these mailer boxes come with flaps that don't need tape or adhesives. You can secure the sealing more by adding dust flaps, cherry locks, magnetic locks, or tuck closures.

Flexibility

You can have these boxes customized to your specifications in any style, shape, and size! You can have them customized with your brand logo or slogan, brand colours, and messages to represent your business.

Shipping Cost

Once again, USPS, FedEx, and UPS frequently provide flat-rate shipping that can only be achieved by utilizing a flexible mailer.

What Are Shipping Boxes?

Shipping boxes, frequently referred to as mailer boxes, corrugated boxes, or cardboard boxes, are made from corrugated sheets. The shipping box types vary in shape based on how they are sealed.

The packaging materials used are Kraft and corrugated boxes, the best and most reliable option where durability is concerned. not only durable but also stylish. Corrugated cardboard is the first choice for many of the business owners, but you can always do customization with the corrugated cardboard boxes.

Before shipping your products in cardboard-based boxes, you must read a comprehensive guide at "How Much Does A Cardboard Box Weigh?" to save taxes.

Types of Shipping boxes

Rigid Boxes

Rigid boxes are the best option in terms of shipping boxes. They are secure and sturdy enough to bear the transit.

Corrugated Boxes

Corrugated cardboard material is specially recommended for shipping.

Folding Cartons

It is made up of paperboard, folded and glued. This is very famous for shipping.

Summary of Shipping Box Specifications
Box Dimensions (cm) Material Points (PT) Ideal For

B1

20 × 15 × 5

Single-wall (B Flute)

28-40

Lightweight items, ideal for domestic shipping within the US.

B2

25 × 20 × 8

Single-wall (B Flute)

32-44

Medium-sized items, good durability, and cost-effective for US shipments.

C2

30 × 25 × 10

Single-wall (C Flute)

36-52

Moderately sized items, enhanced puncture resistance, e.g., electronics and fragile goods within the US.

B2H

25 × 20 × 8

Double-wall (B Flute)

40-60

Medium-sized, heavier items; excellent strength and budget-friendly for US shipping.

C2H

30 × 25 × 12

Double-wall (C Flute)

48-72

Larger, heavier items; superior puncture resistance for electronics and fragile goods in US transport/shipping.

F64

32 × 27 × 6

Double-wall (F Flute)

52-76

Heavy-duty applications; ideal for industrial equipment and high-value goods requiring maximum protection during US shipping.

F65

35 × 25 × 5

Double-wall (F Flute)

56-80

Large, bulky items; exceptional protection against impacts and vibrations for long-distance US shipments.

 

Why To Pick Shipping Boxes

Durability

Corrugated boxes are hard and well-known for their protective characteristics. They are the best option for a product with the highest protection when the product is being shipped.

Lightweight

These boxes are lightweight, and they are known for this feature because they do not add extra weight to the product for shipping purposes.

Customization

Any kind of customization can be done according to the size of the product; the size can be worked on, and the design of the product can be customized.

Heavier Items

For heavier items, Shipping boxes are the perfect pick, as they are used for transit options and also used because the shipping box can withstand the weight of heavy items.

Fragile Items

Shipping boxes give support to fragile items and are easily delivered to the destination on time.

Mailer Boxes vs Shipping Boxes: Which One Is The Best For Your Business

mailer boxes vs shipping boxes

 

That's entirely up to your business. To help you out, here's a quick checklist!

Product Type and Size

Think about what you are shipping. Mailer boxes are great for shipping smaller, flatter items, while shipping boxes can cover all shapes and sizes.

Branding and Unboxing Experience

If the unboxing experience is something special for you, mailer boxes might be suitable in this case.

Shipping Costs

Mailers can work out cheaper if you're shipping medium to small items - plus, shipping boxes have more shipping fees associated with them if you are shipping larger products. Also, if you wanted exclusive rigid mailer shipping costs, that too would be a cost increase.

Sustainability Goals

If sustainability is something you value, pick sustainable packaging that matches your values.

Customization Needs

Decide how far you want to customize frames to represent your brand.

Product Volume

If you ship products and do so regularly, you might find that shipping boxes is a better option for cost-effective practicality.

Overall, with whatever you decide upon, either mailer boxes or shipping boxes, it is highly advised to get the highest quality boxes you can that fit your budget from trustworthy suppliers like MyBoxPrinting.

Mailer Boxes and Shipping Boxes: What’s The Difference?

Mailer Boxes VS Shipping Boxes
Feature Mailing Boxes Shipping Boxes

Material

Lighter materials

Corrugated layers for strength

Protection

Suitable for lightweight items

Suitable for heavier, fragile products

Environmental Factors

Lower carbon footprint

Higher material usage

Aesthetic Appeal

Customizable and visually appealing

Can be branded for enhanced experience

Cost Efficiency

More competitive unit costs

Usually lower cost per unit

Shipping Costs

More budget-friendly due to its lighter weight and flat-rate shipping options.

Typically, higher shipping costs are due to the larger size and weight.

Eco-Friendliness

It can be eco-conscious, especially if using recyclable or lighter materials.

Often eco-friendly, especially with recycled corrugated cardboard.

 

Shipping Boxes and Mailer Boxes: When To Choose

At first glance, shipping boxes and mailer boxes might look alike, but they serve different purposes in the world of packaging and delivery.

Shipping Boxes At A Glance

Shipping boxes are meant primarily for protection during typically long-distance shipping and when packages are heavily handled. They are usually constructed from heavier gauge corrugated cardboard (thick fluting) so they have the rigidity to withstand stacking, heavy items, and rough handling. Shipping boxes are typically a plain brown color or with limited printing, as shipping boxes are functional as opposed to aesthetically pleasing. In addition, these boxes require packing tape to stay shut, and they are ideal for bulk shipments, commercial quantity wholesale, or shipping large or heavy products.

Mailer Boxes In A Nutshell

On the other hand, mailer boxes are designed for a combination of protection and presentation. While they are also corrugated cardboard, they often feature a cleaner design with self-locking or tuck-in flaps, so no tape is needed! The mailer box is often customized with full-color print, logos, and branding to enhance the customer unboxing experience, making the mailer boxes a better option for e-commerce shipments, subscription boxes, gifts, and premium products where first impressions are everything.

Wholesale Custom Mailer and Shipping Boxes At MyBoxPrinting

At MyBoxPrinting, we offer the best and affordable prices for bulk orders. Not only are the prices unbeatable, but the quality is unmatched. It's luxury and premium.

You can always contact us for further assistance, mainly regarding the size of the boxes and the top-notch quality. We are here to give you the best deals so that you don't miss the discount.

Unbeatable Prices: Get An Instant Quote

We at MyBoxPrinting offer unbeatable prices for our premium quality. Feel free to contact us to get a free quote for custom boxes at a wholesale price.

Free Logo and Design Services: Succeed With Customization

 If you want logo services or design services, our team is up-to-date in this regard and gives the best design services. 

No MOQ

There is no minimum requirement for your order; you can order as much as you want.

Free & Ultra Fast Shipping 

We offer fast shipping across the United States of America within 9 to 12 working days after you place an order.

Order shipping or mailer boxes at wholesale prices from myboxprinting.

We have another comparison blog "Mylar Bags vs Rigid Boxes" that helps you to choose the right one packaging to elevate your brand and enhance the revenue.

Frequently Asked Questions

How much protection is needed?

Mailers generally contain less paper and glue than shipping boxes (hence less environmental footprint) and may be less protective. So if you are shipping fragile items, think twice unless they are small and you can use bubble wrap.

How frequently are they being shipped?

Generally, shipping boxes can be reused 4-5 times, depending upon the shipping method, whereas mailers should be used when you ship something for the last time. So spend some time thinking through the one-time use of your packaging.

What is the size and weight of the product or package?

Shipping boxes cost more to ship than mailers; however, they typically hold more weight, and they are larger. Shipping heavier items in a mailer can be more of a challenge than expected.

How much is your budget?

Shipping boxes will cost more in terms of the amount you pay per box and per shipment, but if you can capture that in the price of the item in advance without a negative effect, it doesn't matter.

What is your frequency of shipping?

Be thinking about how much you need to pack these shipments, and walk through using a mailer and a shipping box.

Sum Up!

In summary, if you want the option with maximum durability and cost efficiency, shipping boxes are better overall. If you prefer packaging that is sturdy but also embraces your brand's presentation, the mailer box is your choice.