Choosing Between Corrugated and Paperboard Mailer Boxes
Compare key features to pick the best mailer box for your products.
You want packaging that keeps your products safe and looks good. You need to pick between corrugated mailer boxes and paperboard mailer boxes. Think about how much protection your items need. Think about your budget and your branding goals too. Corrugated mailer boxes are strong because they have fluted walls. Paperboard mailer boxes are light and have a smooth surface for printing. A mailer box supplier can help you compare these choices. They can help you pick the best one for your shipping needs.
Key Takeaways
Corrugated mailer boxes have strong layers. These layers protect heavy items. They also protect fragile items during shipping.
Paperboard mailer boxes are light. They have smooth surfaces. They are good for light products. They are great for bright branding.
Pick corrugated boxes for long trips. Use them for fragile goods. This helps lower damage risks.
Paperboard boxes cost less to ship. They are good for local delivery. They work well for items that are not delicate.
Both box types can be customized. Corrugated boxes have more size choices. They also have more strength choices.
Both boxes are recycled a lot. Corrugated boxes get recycled more often. Paperboard boxes use less material.
Work with a mailer box supplier. They can help match your product needs. They can help with budget, branding, and environmental goals.
Think about product size and fragility. Think about shipping distance and budget. This helps you pick the best mailer box for your business.
Corrugated Mailer Boxes
Features
Strength
Corrugated mailer boxes are strong because they have three layers. There are two flat linerboards and a fluted layer in the middle. This design makes the box tough. The fluted part helps absorb shocks. It stops the box from getting crushed. You can pick single-wall, double-wall, or triple-wall boxes. Each type gives a different amount of protection. If you send heavy or breakable things, this box keeps them safe.
Durability
You want packaging that stays strong during shipping. Corrugated mailer boxes last a long time. Glue holds the layers together so the box does not fall apart. The fluted core makes the box stiff. It helps stop holes and crushing. Many boxes use recycled materials. They can be recycled again, which is good for the planet. A mailer box supplier can help you pick the right box for your needs.
Cushioning
The fluted walls inside the box give natural padding. This padding absorbs bumps and shocks when shipping. There are different flute types like A-Flute and E-Flute. A-Flute is thick and good for breakable things. E-Flute is thin and works for delicate items. The padding keeps your products safe from shaking and hits.
Best Uses
Fragile Products
Use corrugated mailer boxes for breakable items. Electronics, glassware, art, jewelry, and ceramics need extra protection. The layers help stop damage from bumps.
Long-Distance Shipping
If you ship things far away, these boxes are a good choice. The strong walls and padding protect your stuff from rough handling. Your items are less likely to get damaged.
E-commerce
Online stores use corrugated mailer boxes to ship safely. You can send makeup, food, medicine, and even heavy tools. The boxes help show off your brand and keep products safe until they arrive.
Pros and Cons
Advantages
Corrugated mailer boxes have many good points for your business:
Light weight helps lower shipping costs.
Layers give great protection and last long.
Made with recycled materials and can be recycled.
Easy to customize for your brand.
Special coatings can help keep out water.
Disadvantages
A mailer box supplier can help you choose the best corrugated mailer box. You get strong packaging that keeps your items safe and helps your brand.
Paperboard Mailer Boxes
Features
Lightweight
Paperboard mailer boxes are much lighter than corrugated mailers. They have only one layer made from pressed pulp fibers. This makes the box stiff but still easy to carry. You can ship more boxes at once because they weigh less. This helps you save money on shipping, especially for light things. Many mailer box suppliers have paperboard boxes that are strong but not heavy.
Print Surface
Paperboard mailer boxes have a smooth surface for printing. You can add bright colors and clear logos. Detailed pictures look good on these boxes. This helps your packaging stand out in stores or in the mail. Special coatings can make the box shiny or dull. You can work with a mailer box supplier to make custom designs for your brand.
Material Use
Paperboard mailer boxes use less material than corrugated boxes. They are made by cutting and folding one sheet of paperboard. Sometimes, coatings are added to help keep out water. There are different grades like solid bleached sulfate and coated unbleached kraft. Some boxes use natural kraft paper for an eco-friendly look. Mailer box suppliers can help you pick the right material for your needs and budget.
Best Uses
Light Items
Paperboard mailer boxes are good for light products. They work well for clothes, books, small electronics, and makeup. The single layer protects items that do not need lots of padding. You get protection and save money at the same time.
Retail
Retailers like paperboard mailer boxes for their clean look. They are easy to brand. You see them used for food, beauty items, and small goods. The table below shows how different industries use these boxes:
Subscription Boxes
Subscription box companies often use paperboard mailer boxes. These boxes are stiff enough to protect things during shipping. You can change the size, shape, and design to match your brand. This makes opening the box fun for your customers.
Tip: A mailer box supplier can help you design subscription boxes that show off your brand and keep your products safe.
Pros and Cons
Advantages
Light boxes help lower shipping costs.
Smooth surface is great for printing and branding.
Custom sizes and shapes fit your products well.
Eco-friendly choices include recyclable and compostable boxes.
Easy to put together and store, saving time and space.
Disadvantages
Not as much protection for heavy or breakable items.
Products can get damaged if the box is too big or packed badly.
Using too much packing can waste materials and cost more.
Some people think breaking down boxes for recycling is hard.
Stores may have trouble balancing protection, cost, and being green.
You can work with a mailer box supplier to find the best paperboard mailer box for your products. This helps you balance safety, cost, and branding while meeting your green goals.
Comparison
Protection
Protection is very important when picking packaging. Corrugated mailer boxes and paperboard mailer boxes keep products safe in different ways. Corrugated mailer boxes have fluted layers. These layers make the box strong and help absorb shocks. This keeps fragile and heavy things safe when shipping. Paperboard mailer boxes use one pressed paper layer. They feel stiff but do not protect well from drops or crushing.
You can see the difference in this table:
If you ship breakable or expensive things, corrugated mailer boxes help you worry less. For light and less delicate items, paperboard mailer boxes are fine. A mailer box supplier can help you pick the right box for your product.
Cost
Cost is a big part of choosing packaging. Corrugated mailer boxes cost more because they use more material and give better protection. Paperboard mailer boxes cost less and you save more when you buy a lot.
Here is a price comparison for different order sizes:
You save more money per box with paperboard mailer boxes when you order more. If you want to spend less, especially for big orders, paperboard mailer boxes are a better deal. A mailer box supplier can help you find the best price for your budget and order size.
Customization
You want your packaging to show off your brand. Both corrugated and paperboard mailer boxes can be customized, but they offer different choices.
Corrugated mailer boxes give you lots of options. You can choose many sizes, shapes, and strengths. You can add more layers for extra protection. Printing choices include digital CMYK, flexographic, and lithographic methods. These boxes can have bright colors and detailed designs. You can use online design tools, templates, and 3D editors to make your box. Proofs and samples let you check your design before you order a lot.
Paperboard mailer boxes also let you print custom designs. The smooth surface makes pictures and logos look clear and bright. You can add things like windows, tear strips, or resealable pouches. But there are fewer choices for size and strength. These boxes are best for light items and fancy graphics.
Tip: If you want strong branding and special packaging, corrugated mailer boxes give you more choices. For simple and bright designs on light products, paperboard mailer boxes work well. A mailer box supplier can help you customize both types.
Sustainability
When you pick packaging, you should think about the planet. Both corrugated mailer boxes and paperboard mailer boxes are good for the environment, but they are different in some ways. Corrugated mailer boxes have many layers of paper. These layers are often made from recycled stuff. You can recycle these boxes after you use them. The EPA said that in 2018, about 96.5% of corrugated boxes were recycled in the United States. This makes them the most recycled paper packaging in the country. New data shows the recycling rate for corrugated mailer boxes is between 66% and 93.6%. The number depends on how people count it. Because so many get recycled, you help keep trash out of landfills when you use corrugated mailer boxes.
Paperboard mailer boxes can be recycled too. In 2018, about 80.9% of paperboard packaging was recycled. This includes folding cartons and set-up boxes. That number is good, but not as high as corrugated mailer boxes. Paperboard mailer boxes use less material. This means they need fewer resources and weigh less when shipped. Many paperboard boxes are made from recycled paper or from forests that are managed well.
Here is a quick comparison:
Tip: If you want the best recycling rate, pick corrugated mailer boxes. If you want to use less material and make shipping greener, paperboard mailer boxes are lighter. A mailer box supplier can help you choose packaging that fits your green goals.
Mailer Box Supplier Considerations
Product Type
You need to pick packaging that fits your product. A mailer box supplier will ask about your product’s size, shape, weight, and if it is breakable. These things help you choose the right box. Heavy or odd-shaped products need strong corrugated mailer boxes with extra inserts. Light or flat items can use paperboard mailer boxes.
Key product characteristics to consider:
Size
Shape
Fragility
Shelf-life
Weight
If your product is fragile, look for boxes with more padding or inserts. Products that move inside the box can break. A mailer box supplier can help you pick the best box style. Regular slotted corrugated boxes work for heavy things. Mailer boxes with interlocking flaps are good for e-commerce. You also need to think about moisture. Some products need double-walled or coated boxes to stay safe. If you use the wrong box, your products might get damaged and sent back. Custom box sizes and inserts can help stop this.
Tip: Always tell your mailer box supplier about your product. This helps them find the safest and cheapest packaging.
Shipping Distance
How far you ship changes the box you need. If you ship far, your packaging gets more bumps and handling. Corrugated mailer boxes are best for long trips. They have strong walls that stop crushing, bursting, and holes. This makes them good for fragile, heavy, or valuable things.
For short trips, you can use paperboard mailer boxes for light, non-breakable products. These boxes cost less and weigh less, so you save money. A mailer box supplier can help you balance safety and cost for your shipping routes.
Corrugated mailer boxes: Best for long trips and rough handling.
Paperboard mailer boxes: Good for local trips and less breakable goods.
If you ship both near and far, ask your mailer box supplier for help. They can help you pick the right box for each trip.
Branding
Branding is important if you want your packaging to stand out. Both corrugated and paperboard mailer boxes let you show off your brand. A mailer box supplier can help you use full-color printing inside and outside your boxes. You can pick finishes like matte, gloss, kraft, or soft-touch. These finishes make your artwork look better and protect the box.
You can also pick custom sizes, shapes, and inserts. These features help your products fit well and make opening the box special. Some mailer box suppliers offer self-locking closures, tuck-in flaps, tear strips, and sticky tape seals. These choices add style and make your packaging easy to open.
Note: Ask your mailer box supplier about eco-friendly inks and coatings. These choices help your brand look good and help the planet.
Budget
You want to spend less on packaging. Your budget helps you pick the right mailer box. A mailer box supplier can help you get the best deal. Here are some things to think about: You should find boxes that are cheap but still good quality. Ask your mailer box supplier if you can get a lower price for buying a lot. Buying more boxes at once usually makes each box cost less. The material you pick matters. Corrugated boxes cost more than paperboard boxes. They use more material and protect better. Paperboard boxes are cheaper and work for light things. Custom printing and special finishes can make boxes cost more. Make sure your box looks good but does not cost too much. If your box is too thin, your products can break. This can make customers upset and cost you more money. You need to think about protection, looks, and price. Sometimes, paying a little more for a strong box saves money later because it stops damage.
Tip: Talk with your mailer box supplier about all your choices. They can help you look at prices, materials, and features so you get the best deal.
Environmental Goals
You might want your packaging to help the environment. When you look at mailer box suppliers, find ones with green packaging. These certifications show the supplier uses good and safe materials.
You should ask your mailer box supplier about these green certifications. For example, FSC certification checks where the paper comes from. This helps you and your customers know your packaging is good for forests. Picking a mailer box supplier with green awards helps you reach your eco goals. It also shows your customers you care about the earth.
Picking between corrugated and paperboard mailer boxes is not always easy. You need to think about your product, how you ship, your brand, your budget, and if you want to help the planet. Here is a checklist to help you choose:
Pick the box that fits your product’s weight and if it can break
Think about how much protection you need and how fun it is to open
Look at shipping prices and how much space you need to store boxes
Check if you can change the box design and if it is good for the earth
A mailer box supplier can help you find the right materials. They can help you keep your products safe and make your packaging look great. Their help makes sure your packaging works for your business and makes your customers happy.
FAQ
What is the main difference between corrugated and paperboard mailer boxes?
Corrugated mailer boxes have fluted layers inside for strength. Paperboard mailer boxes use one pressed sheet, so they are lighter and smoother. You should talk to your mailer box supplier to see which fits your product best.
Which mailer box is better for fragile items?
Corrugated mailer boxes are better for fragile things. The fluted layers help stop shocks and damage. Ask your mailer box supplier which flute type is best for your products.
Can I print custom designs on both types of mailer boxes?
You can print custom designs on both kinds of boxes. Paperboard mailer boxes have a smooth surface for clear pictures. Corrugated mailer boxes can also show bright prints. Your mailer box supplier can show you samples of each.
Which option is more eco-friendly?
Both types use materials that can be recycled. Corrugated mailer boxes get recycled more often. Paperboard mailer boxes use less material and are lighter. Talk to your mailer box supplier about your green goals to pick the best one.
How do shipping costs compare between the two?
Paperboard mailer boxes weigh less, so shipping is cheaper for light things. Corrugated mailer boxes cost more to ship but protect heavy or breakable items better. Your mailer box supplier can help you figure out shipping costs for each box.
Are both mailer box types suitable for e-commerce?
Both types work for e-commerce stores. Corrugated mailer boxes are best for heavy or breakable things. Paperboard mailer boxes are good for light, non-breakable items. A mailer box supplier can help you pick the right box for your online shop.
How do I choose the right mailer box supplier?
Pick a mailer box supplier who knows both types well. They should give you samples, let you customize, and offer green choices. Ask about prices, order sizes, and how they help your business.
Can I get custom sizes for both corrugated and paperboard mailer boxes?
You can get custom sizes for both types of boxes. A mailer box supplier can help you design boxes that fit your products well. This helps stop waste and keeps your items safe.
