The same 1.5 pound sweater could be billed as a 10 pound package when it is shipped in a stock box which is a few inches larger than it should be. There are charges on the space occupied by a box and charges on the weight and therefore e-commerce packaging with empty space around the item pays that air space each time an order is placed. It is removed by a custom mailer box that has been cut to the product. Empress Packaging produces online brand mailer boxes in the USA of any size based on the actual size of the product.

The decision of how much a box costs by carriers.

The rates of shipping products are charged on the basis of billable weight which is the larger of the actual weight of a parcel and the dimensional weight. Dimensional weight is the cubic inches of outside volume divided by a given number and rounded off to the next pound. Many domestic rates of UPS and FedEx have 139, and USPS in July 2026 shifted the divisor to 139 with parcels over one cubic foot, so verify the divisor in your own deal. Stock shipping containers have pre-determined sizes and therefore an item with a flat surface is left with unutilized space. With 1,344 cubic inches, a 14 x 12 x 8 inch box weighs 10 pounds and costs 10 pounds billed by UPS or FedEx. The 360 cubic inches is 3 pounds and the custom mailer size is 12 x 10 x 3 inches. Precise cut to size ecommerce packaging also requires minimal void fill and snug fit prevents the product to slide during transit.

Quickly packing with a reduced amount of material.

A tuck-top mailer comes flat and is folded into shape within seconds. It does not use tape, and thus a packer with a few hundred orders a shift avoids the use of the tape gun on each. The space required by assembled shipping boxes is also a fraction of that required by flat mailers. Most US curbside programs accept plain corrugated, and recycled-content and FSC-certified stock is available.

What the customer looks at at the door.

A mailer is a printed mailer with the brand displayed on the porch and once again when the lid is opened. Banded packaging may be one-color on kraft, or a complete wrap. Gift brands may borrow the finishes of luxury packaging boxes, e.g. soft-touch lamination or foil, and use them on the mailer. It resembles a stiff gift box more, but it also ships flat and is much lighter. In the event the product is also stocked on store shelves, the mailer can also include the same artwork as used on the retail package, which makes both read as a single brand.

What products would be appropriate with a custom mailer?

Mailers are ideal with flat or low profile products like apparel, books, stationery and small beauty sets. Tall, heavy, and delicate bottles should have a more structure or an insert.

• Closures, size, and stock.

Product shipping is sliced to the length, width and depth of the product with space to fold over. Stock is kraft or white corrugated and closures are tuck tops and tear strips. Request minimums with quote, as these are by size and print.

FAQs

Q: What will a custom mailer reduce my shipping bill?

A: It will be based on your carrier rates and your existing box. Divide the billable weight of each by the carrier weight listed on your carrier and charge the difference at your rate.

Q: Does custom mailer safeguard delicate products?

A: Light and delicate objects are secured by a die-cut insert. Breakable or heavy should be boarded with two walls, hence providing the supplier with the weight of the product.

Q: Is it possible to have a single size to represent multiple products?

A: Yes, when they are similar in size and smaller sizes also favour volume pricing.

Q: Are custom mailers required to be taped?

A: Tuck-top mailers are closed without. An easy-open or tamper-evident seal is provided with a tear strip or seal sticker.

Get a free quote on custom mailers.

Provide your product dimensions, weight and volume of orders per month and Empress Packaging will quote mailers of size. A free quote can be requested at empresspackaging.com, by emailing query@empresspackaging.com  or by calling (888) 900-7629.