An E-flute corrugated mailer with a full-color printed interior and an all-paper die-cut insert that cradles every part with no plastic. Plain kraft outside, branded reveal inside. Built for bathroom and sanitary kits shipped direct to customers.
A litho-laminated corrugated box that ships flat as a mailer, then opens into a branded counter display with a pop-up header card. Full color with anti-scratch matte for dark designs. Built for retail and point-of-sale promotions.
Custom corrugated mailer box with tab lock roll end structure, self-seal adhesive closure, and tear strip opening. Available in kraft or printed finish, with optional inserts for organized packing.
This is a die-cut display box that does two jobs. It ships flat and seals as a mailer, then the lid folds up into a standing header card so the open box works as a branded counter display. The whole surface is litho-laminated for full-color print, with an anti-scratch matte finish that keeps dark designs from scuffing in transit. It suits retail merchandise, promotional kits, and point-of-sale displays where the pack has to survive shipping and then sell on a shelf or counter.
| Option | Standard | Customizable range |
|---|---|---|
| Box style | Die-cut mailer with pop-up display header | Tray-and-lid, PDQ shelf tray, RSC with display panel |
| Board and flute | B-flute litho-laminated corrugated | E-flute, or E/B double-wall for larger displays |
| Print method | Offset litho-lamination, full color (CMYK) | Flexo line work; 1 to 2 spot colors |
| Brand color | CMYK process build | Pantone spot for flat brand colors, matched to an agreed tolerance |
| Surface finish | Anti-scratch matte lamination | Gloss, soft-touch, spot UV, foil stamping |
| Display header | Die-cut arched header card | Custom shape and height, double-sided print |
| Closure | Self-locking die-cut | Tuck front, tear-strip easy open |
| Dieline and size | Engineered to your product | Send dimensions for a fitted dieline and a sample |
| Eco options | Recyclable corrugated | FSC-certified board and recycled content on request |
The same pack moves product and sells it. Closed, it is a flat self-locking mailer that protects the contents through parcel or pallet shipping. On the counter, the front folds down and the lid stands up as a printed header card, turning the box into a shelf-ready display without a separate stand. This removes the cost and assembly of a standalone display unit and gives retail staff a pack they can set out in seconds.
Dense black and dark patterns are the hardest print to keep clean, so the finish matters more than the file. We print by offset litho-lamination, which laminates a full-color sheet to the corrugated for photographic quality, then apply anti-scratch matte film. Matte film stops the grey scuffing that bare dark solids pick up in transit, and it holds the rich look the design depends on. For a flat brand color that has to stay consistent across reorders, we recommend a Pantone spot rather than a four-color build, since heavy CMYK solids drift run to run. Color is managed to G7 with X-Rite measurement and signed off on a contract proof.
The standing header is die-cut to your shape and prints on both faces, so it reads from the front and carries branding or a QR code on the back. Because the artwork has heavy ink over the fold lines, we score to the grain direction and check crack risk at the dieline stage, so the panels fold crisp without the ink cracking along the crease. Header height and shape are part of the structural design, not a fixed template.
The box is engineered for both jobs at once. B-flute gives the rigidity the header needs to stand while keeping a smooth print face, and wall strength is set from the contents weight, transport mode, and stack height, then verified on our in-house tester with compression and burst checks. We design to ISTA 3A or retail parcel requirements and provide our test data so you can certify through your own lab if a channel requires it.
The structure is single-material corrugated, which keeps it recyclable in the standard paper stream. FSC-certified board and recycled content are available on request. Anti-scratch matte is a film lamination, so where a fully repulpable spec is required we can review an aqueous matte coating as an alternative against your destination market rules before artwork.
Send your product dimensions, target quantity, artwork, and the retail setting the display goes into, and we return an engineered dieline, a recommended spec, and a quote. We can ship a blank structural sample or a printed digital proof for your approval before the run. Production is offset litho-lamination built for export volumes on a Komori and KBA press fleet, with no strict minimum, though unit cost drops with quantity. Certifications on file include ISO 9001 and 14001, FSC chain of custody, G7, and GMI.
Does it ship flat and assemble without tools?
Yes. It ships flat to save freight and folds up by hand with a self-locking close, no tape or glue at the store. The header is part of the same blank, so there is no separate piece to attach.
What order quantity makes sense?
There is no strict minimum, but litho-lamination has plate and setup costs that spread over the run, so small batches carry a higher unit cost and the price falls with volume. Tell us your launch quantity and reorder forecast and we will advise on the break points.
Can you design the box and header to fit my product?
Yes. Structural design is in-house. Send the product dimensions and weight, or a sample, and we return a fitted dieline with the header shape you want, plus a physical sample before you commit to a run.
What is the lead time?
It depends on artwork sign-off, sampling, and quantity. A typical project moves from approved dieline to sample to production over a few weeks, and we confirm a firm schedule with your quote once the spec is set.
Can you match our brand colors across reorders?
Yes. We match to an agreed tolerance on a defined board and sign off on a contract proof. For a flat brand color we recommend a Pantone spot so it holds consistent from one print run to the next.
