Mailer Boxes: Where E-Commerce Packaging Actually Gets Tested

The mailer box goes through a different life cycle than other packaging solutions. It doesn't lie on a shelf waiting to be retrieved. Even before it reaches its recipient, it's stacked, tossed, dropped, rained on, shoved into delivery vans, and dozens of other packages. On that trip it will inform you whether it was a well-designed mailer box or a well-designed box to look good in a product shot.

Why Shelf Testing Doesn't Tell the Whole Story

Shelf testing is not a sufficient way of assessing food safety. Shelf testing is not a complete assessment method for food safety.

Designing a mailer box that will really look fantastic on a desk is easy. The only real test occurs when it gets into the shipping stream and that is where many packaging decisions go unspoken. What may appear solid and secure while in the office can actually jar and shift after a few hours traveling, particularly if it's piled on top of heavier packages or picked up and dropped promptly at a sorting center.

What Actually Happens During Shipping

We don't calculate the cost of shipping for you. We don't charge you for shipping.

Most people don't realize what you put a parcel through, but it is a good idea to do it as straight as you can:

* Multiple handling points, with sometimes little attention paid at each point

* Place under boxes containing positions of random weights and shape

* Exposure to high and low temperatures, exposure to occasional moisture or rough weather.

* There can be sudden drops or impacts during loading and unloading. The load/unloading process may experience sudden drop or impact.

* It has to travel a long distance to get to other places and the distance to the latter is very high.

No matter how attractive the mailer box appears on the outside, it is just a hunch until it's proven by these facts.

By Staff at Wildcats, Inc. By the Staff of Wild Cats, Inc.

Structural Choices That Matter More Than Looks

Printing and branding can't even be a consideration until structure can stand up. There are some decisions that have more impact than most would realise:

Flap Design

Flaps which are poorly reinforced are one of the most common failure points, particularly on boxes which are stacked heavily.

Corner Strength

Corners are the places where drop damage occurs, and when handled roughly, the first impression damage can be prevented with reinforced corners.

Material Weight

On the technical side, it is not always necessary to choose board that will be strong enough, since there can be an effect of stacking pressure in reality longer shipping distances.

Branding Still Matters — Just Not First

This is by no means the first time a brand has made a comeback. The comeback is not the first for a brand.

Yes, there has been structure established, now it's time to have a mailer box stand for the business; that's where branding comes in. When businesses are interested in print custom mailer boxes​ they generally spend a considerable amount of time considering the colour and where the logo will be positioned on the box, however only when they receive the box in good condition. The beautifully printed box is going to look worse when it arrives to the shelf in a crushed condition than the unspectacular box.

Comparing Mailer Box Options

There are two options available for Mailer Box.

| Type | Best For | Shipping Durability |

| Colorful and Lead Free (SWC) | Light items | Moderate |

| Double-Wall Corrugated | Heavier or fragile products | High |

| Printed Kraft Mailer | Brand-centric e-commerce | Moderate to High |

| Reinforced Corner Mailer | Long-distance shipping | High |

| Standard Cardboard Mailer | Budget shipping, low risk items | Low to Moderate |

Questions Worth Asking Before Committing to a Box

There are certain questions that need to be asked prior to signing up for a box.

- Has a box been dropped from a desk or been placed in a real shipping environment?

- Can the flap stacked weight hold for a couple of hours?

- Would the print design be effective in a rough handling situation?

- Is it a default material or does the material need to be selected based on the actual weight of the product?

A Quick Pre-Shipping Checklist

This is a brief checklist that you can go through before you ship.

☐ Check box which will lift the real weight of product rather than size

☐ Check corners and flaps for strength at moderate pressure by bending

☐ Test the durability of the print when scuffed and/or wet.

☐ Review return/damage data if packaging is used for an extended period of time.

Frequently Asked Questions

Poor performance in mailer boxes is not uncommon, although they seem to be quite strong?

Sturdiness is not just indicated by the visual appearance; overall board thickness, as well as the strength of the flaps and corner reinforcement, are also key.

Does double-wall corrugated always need to be used for e-commerce shipping?

Not always, depending upon product weight and fragility, but if more durable product type, then it may not be worth returning for if heavier or fragile.

If the box is damaged in transit, does the quality of the brand have an impact on the customer's perception?

Yes, of course, even a great box with great printing will be worse than a plain undamaged box.

How do businesses ensure their boxes are mailed?

Routine one of the best practices for early detection of structural issues is to order a small batch sample and send out a few test parcels to different areas.

Final Thoughts

The real question with any mailer box is not if it gets on the table at the design meeting, but if it makes it to the doorstep of a customer after clanging around in the delivery van or in a sorting center. Building the structure before the branding is put in place can help to avoid any kind of harm that inflicts greater losses on businesses in terms of returns and loss of trust than a branding would have originated in the first place.