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 self-locking corrugated mailer with a die-cut EPE foam insert. The foam is contoured so each part sits in its own cavity, which stops the contents moving and cushions fragile items like glass vials and bottles through parcel handling. The board is kraft in E, B, or BE double-wall flute, sized to the weight and fragility of the contents. It is made for kits, sample sets, cosmetics, glassware, and small electronics shipped direct to customers.
| Option | Standard | Customizable range |
|---|---|---|
| Box style | Self-locking corrugated mailer | Tuck-top, full-overlap, two-piece tray and lid |
| Board and flute | Kraft E-flute | B-flute, or BE 5-ply double-wall for heavier or fragile loads |
| Insert | Die-cut EPE foam contour nest | All-paper die-cut insert, EPE and corrugated hybrid, anti-static EPE |
| Foam density | Matched to product weight and fragility | Softer for light fragile items, firmer for heavy |
| Closure | Self-lock tuck | Tear-strip, double seal for returns |
| Plain, or 1-color on kraft | Full color, inside print | |
| Size | Engineered to your contents | Any size, custom dieline and insert |
| Eco options | Recyclable kraft; EPE recycles in the PE stream | All-paper plastic-free insert, FSC board on request |
The foam nest is what protects the product. Each item drops into a contour cut to its shape, so nothing rubs against another part or rattles loose, and the foam absorbs the shock of a parcel drop before it reaches the contents. Foam density is matched to the job, softer for light fragile items so they are not bruised, firmer for heavier parts that need to be held. We design the cavity layout to your exact kit and confirm the cushioning against the drop height the parcel will see.
The foam is sized for the drop and the box for the stack. The insert handles impact, while the corrugated wall carries the stacking and compression load of transit and storage. Kraft E-flute suits light kits, B-flute adds wall strength, and BE 5-ply double-wall is the choice for heavy or highly fragile loads or long sea-freight stacks. We set the flute from the contents weight, transport mode, and stack height, then verify it on our in-house tester with compression and burst checks.
You choose the insert by your priority. EPE foam gives the softest cushioning for glass and finished surfaces and is recyclable in the polyethylene stream and reusable, but it is a plastic. Where a plastic-free or single-material spec is required, an all-paper die-cut insert holds and protects most kits with no foam at all, and recycles with the box. For electronics, anti-static EPE is available. We will recommend the insert that fits both the fragility and the eco mandate you give us.
Print runs light on this pack. Kraft takes a one-color logo or inside-lid message in water-based ink, with full color available when the unboxing matters. To quote, send the contents and their weights, the dimensions, your target quantity, and the destination, and we return an engineered dieline, an insert design, a recommended board, and a price. We can ship a blank structural sample or a printed digital proof for your approval before the run. There is no strict minimum, though unit cost drops with volume. FSC chain of custody, ISO 9001, and ISO 14001 are on file.
How do you know the foam will protect my product?
We size the foam from the product weight, its fragility, and the drop height a parcel sees, then check the cushioning before production. Send a sample of the kit and we design the cavity and confirm the density rather than guessing at it.
Can I avoid plastic foam entirely?
Yes. An all-paper die-cut insert replaces the foam for most kits and recycles with the box. EPE foam stays the better choice for glass and delicate finishes, so we match the insert to your fragility and eco priority.
What order quantity makes sense?
There is no strict minimum, but the foam tooling and box setup 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.
What is the lead time?
It depends on the insert design, sampling, and quantity. A typical project moves from approved dieline and foam design to sample to production over a few weeks, and we confirm a firm schedule with your quote.
Do you handle international shipping?
Yes. We export under standard Incoterms such as FOB and CIF, and we advise on carton and pallet fit, with humidity derating on the board spec for long sea-freight stacks so the box holds up.
