Custom mailer boxes cost more or less depending on size, board, print coverage, finish, insert and quantity. A small kraft mailer printed in one color is at the low end, and a large white mailer with full-coverage print, an inside print and an insert is at the high end. TBPB has no minimum order, and we beat any written quote for the same specifications.
Reviewed by the TBPB packaging team, October 2026.
| What moves the price | Lower cost | Higher cost |
|---|---|---|
| Size | Smaller footprint, less board | Larger box, more board |
| Board | Kraft corrugated | White-faced or heavier corrugated |
| One color outside | Full color outside and inside | |
| Insert | None | Custom insert or divider |
| Finish | None or a simple coating | Specialty finishes (ask us to confirm for your spec) |
| Quantity | Larger runs spread setup | Single boxes carry setup |
What is the biggest driver of mailer box cost?
Size. A mailer is mostly board, so a box that is an inch longer in each direction uses noticeably more of it, and more board means more cost and more weight to ship. The cheapest saving available to most brands is to right-size the box. Measure the product, add only the clearance it needs, and stop. Our mailer box size guide shows how to do that step by step.
Kraft or white: does it change the price?
Usually, yes. Plain kraft is typically the lower-cost face, and it takes one-color print well. A white face takes bright color print better and looks cleaner, and it can cost more. Our kraft versus corrugated comparison covers how each prints and where each fits.
How much does printing add?
Each extra color and each extra surface adds cost. A one-color logo on the lid is the lowest option. Full-coverage color on the outside costs more, and printing the inside, which is the reveal when the customer opens the box, costs more again. If you want the inside print, keep the outside simple. Many brands do the reverse and put the surprise inside.
Do inserts and extras change the cost?
Yes. An insert adds a part, a cut and a fit. It earns its cost when the product is fragile or when you ship several items together. If the product already sits snug, skip it. For the styles we make, see the mailer box range, the kraft mailer boxes and the luxury mailer boxes.
How do I read a mailer box quote?
Look for six lines. First, the box size and if it is inside or outside. Second, the board and its strength rating. Third, the print: colors and which surfaces. Fourth, any finish. Fifth, the insert. Sixth, the quantity and what shipping and design help include. If any line is missing, ask for it in writing. A quote that says only “mailer box, 1,000 units” cannot be compared with anything.
Worked example: 500 mailers, 10 x 8 x 3 inches inside. Quote A: single-wall kraft, one-color print outside, no insert, shipping extra. Quote B: single-wall white, four-color outside, one-color inside, a paperboard insert, shipping included. B is the larger number and also the larger box on four lines. Compare them line by line, and send us whichever one you prefer: we build that spec and beat the written price.
How can I lower the cost without hurting the box?
- Right-size the box. Measure the product and add only the clearance it needs.
- Print one color outside and keep the inside plain, or the reverse.
- Use kraft where the brand fits it.
- Standardize on two or three box sizes for the whole range.
- Reorder the same size so the setup is paid once.
How to order
Send the product dimensions, your preferred style and a quantity, even if it is one box. We return a dieline and a quote. Design help, samples and shipping are free. If you have a written quote from another supplier for the same specs, our price-beat guarantee means we beat it. Request a quote here.
Questions buyers ask
How much do custom mailer boxes cost?
It depends on size, board, print, finish, insert and quantity, so one number would mislead. Send your specs and we quote it exactly. We also beat any written quote for the same specifications.
Is there a minimum order for mailer boxes?
No. Order one mailer to test the fit or thousands for a launch. Per-box cost falls as quantity rises because setup is spread across more boxes.
What is the cheapest mailer box?
A small kraft corrugated mailer with one-color print and no insert is usually the lowest-cost route. Right-sizing the box saves more than most other changes.
Does printing the inside cost extra?
Yes. Each added surface and color adds cost. Many brands print the outside simply and put the full-color print inside for the reveal.
Why is one quote cheaper than another?
Often a lighter board, fewer print colors, no insert, or excluded shipping. Compare each line before the total.
How do I get a quote?
Send the dimensions, style and quantity through the quote form. We return a dieline and a price.
