E-commerce and subscription packaging
Custom e-commerce and subscription box packaging
Printed mailer boxes, transit boxes and inserts for UK online retailers and subscription box businesses. We size the box to what you actually send, so it travels well, packs quickly and costs less to post, then print it inside and out so the parcel doubles as your shop window. One design or a monthly programme, orders start from 50 boxes.
Overview
The box is the first thing your customer touches
When you sell online, the delivery box replaces the shop. It is the first physical contact a customer has with your brand, and often the thing they photograph and share. A printed mailer that fits the contents, opens cleanly and reveals a printed interior does more for repeat orders than almost any other packaging spend.
It also has a practical job. The box has to survive being dropped, stacked and thrown into vans, then arrive looking as it did when it left you. And it has to be quick to pack: a construction that folds up in seconds and closes without tape saves real time across hundreds of orders a week.
Subscription boxes add a third demand: consistency with variety. Contents change every month, but the box usually stays the same, so we design an outer and an adjustable or modular insert that handles different product mixes, with seasonal sleeves or stickers for special editions.
Challenges
What goes wrong with e-commerce packaging, and how we specify against it
Crush and drop damage
Parcels are stacked under heavier items and dropped during sorting. We specify flute and board for the weight and fragility of the contents, move from E flute to B flute or double wall as weight rises, and add an insert where items could move.
Oversized boxes and higher postage
A box a few centimetres too big can move an order into a higher postage band and needs void fill to stop the contents rattling. We size mailers to your real product mix and can check external dimensions against the size bands you ship to.
Slow pack-out
Boxes that need taping, folding in several steps or a separate insert slow a packing bench down. Roll-end tuck front mailers set up and close in a few movements, and inserts can be designed to drop straight in.
Scuffed outer print
Printed outers rub against other parcels and conveyor belts. Lamination on the outer print, or a simpler outer with the full design on the inside, keeps the box looking right when it reaches the doorstep.
Changing contents every month
A subscription box that fits one month's products perfectly may not fit the next. We design around your typical range of contents, with an insert that can be adjusted or swapped, so the outer box stays constant.
Returns that arrive damaged
If your customers send products back, the original box is often torn open. Tell us at the brief if returns matter, so the closure and construction can be chosen with a second journey in mind.
Recommended packaging
Recommended packaging for online orders and subscriptions
Product
Custom printed mailer boxes
The standard branded e-commerce box: E flute board, printed inside and out, closes without tape and stacks flat before use.
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Roll-end tuck front mailer boxes
Double-thickness side walls and a front tuck lid make it strong, fast to pack and satisfying to open.
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Printed corrugated boxes
For heavier or bulkier orders, and for outer shippers that carry a presentation box inside.
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Corrugated lid and base boxes
A two-piece corrugated box for subscription and gift boxes where the lid lifts off to reveal the whole collection.
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Custom box inserts
Card or corrugated inserts that hold mixed products in place and replace loose void fill.
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Sleeve boxes
A printed sleeve over a standard mailer for seasonal editions and launches without a new box design.
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Materials
Board and materials for e-commerce packaging
Corrugated board does most of the work in e-commerce. Flute thicknesses below are typical and vary by supplier; the exact board is confirmed on your quotation once we know the contents and weight.
| Specification | Typical range | Notes |
|---|---|---|
| E flute corrugated board | About 1.5 mm | The most common mailer board: a smooth surface for crisp print and enough strength for light-to-medium orders. |
| B flute corrugated board | About 3 mm | For heavier orders and bulkier products that need more crush resistance. |
| Double wall corrugated | About 6–7 mm | For heavy, fragile or high-value contents and outer shippers carrying glass. |
| White-lined or kraft liners | — | White liners give the brightest print; kraft liners give a natural look and suit one or two colours. |
| Folding boxboard (FBB) | 300–400 GSM | For card inserts, dividers and inner cartons inside a subscription box. |
Finishes
Finishes that suit the sector
Printed interiors
The design on the inside of the lid is the first thing seen at opening, and it stays clean in transit.
Matt and gloss lamination
Protects outer print from scuffing in the courier network.
One- or two-colour print on kraft
An economical outer that looks deliberate, often paired with full-colour print inside.
Foil blocking (hot foil stamping)
A foil logo on premium subscription boxes and gift editions.
Branded mailer boxes for online orders
A printed mailer box is the everyday workhorse of online retail. Sized to your most common orders, it protects the contents, carries your brand to the doorstep, and folds flat for storage. Most brands settle on two or three sizes that cover the majority of orders, rather than a different box for every product.
Subscription box programmes
Subscription boxes are ordered repeatedly and opened on camera, so consistency and presentation both matter. We design one outer box and insert system that handles a range of monthly contents, and can quote quantities that match your subscriber numbers and storage space. Seasonal sleeves or stickers mark special editions without changing the core box.
Right-sizing and postal size bands
The external size and weight of a parcel decide which postage band it falls into, so a few millimetres can matter. We size boxes from the contents outwards, allowing for board thickness, and can check the external dimensions against the bands you use. Our size band guide explains the principles.
Inserts and pack-out for mixed products
When a box carries several items, a card or corrugated insert with a place for each keeps them from colliding and makes the box look curated rather than filled. It also speeds packing, because each item has an obvious home, and can reduce or remove the need for loose void fill.
Printed interiors and the unboxing
Printing the inside of a mailer is one of the most effective upgrades in e-commerce packaging. The outer can stay simple and hard-wearing while the interior carries a pattern, a thank-you message or a prompt to share, which is protected from scuffing throughout the journey.
E-commerce and subscription questions
Questions buyers ask
Anything not covered here, put it in the notes on your quote and we will answer it directly.
Ask on your quoteWhat is the best box for shipping products to customers?
For most online orders, a printed E flute mailer box sized to the contents. Heavier or more fragile orders move up to B flute or double wall corrugated, with an insert where items could move.
Can you make a box that fits a postal size band?
Yes. Tell us the band you want to stay within and we will size the box so the external dimensions fit, allowing for board thickness. The contents must fit inside, so we work from both sides.
How many box sizes do I need?
Usually fewer than you think. Send us your product dimensions and typical order combinations and we will suggest the smallest set of sizes that covers most orders without excess space.
Can you print inside the mailer box?
Yes. Interior printing is very common in e-commerce and subscription packaging. It adds a print pass, which is included in the quotation when you ask for it.
Can one subscription box work for different monthly contents?
Yes, if it is designed for it. We size the outer to your typical range of contents and design an insert that can be adjusted or swapped between months.
Do mailer boxes need tape?
A roll-end tuck front mailer closes with a tuck and holds shut without tape. Many brands add a branded sticker or tape for tamper evidence and presentation.
What is the minimum order for mailer boxes?
Orders start from 50 boxes. For subscription programmes, tell us your expected monthly volume and storage space and we will confirm the options on your quotation.
How long does an e-commerce packaging order take?
It depends on the construction, print and quantity. Tell us your required delivery date and our team will confirm whether the timing is achievable. Delivery is included on every order, and your quotation confirms the delivery address and timing.
Ready to specify your packaging?
Our team replies during business hours, 10:00–18:00 UK time.