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Easy Fold Mailer Boxes

Easy fold mailer boxes are a smart and efficient packaging solution designed for quick assembly, secure shipping, and an enhanced unboxing experience. Ideal for eCommerce brands, subscription services, and retail businesses, these boxes feature pre-scored lines and a self-locking design that makes folding fast and tool-free, saving time in packaging operations without compromising on strength. At The Product Boxes UK, we offer custom eco friendly mailer boxes made from durable corrugated or kraft materials that provide excellent protection for a variety of products.

You can personalise every aspect, from size and structure to full-colour printing, foil stamping, matte/gloss finishes, or inside printing to create a branded surprise upon opening. Whether you need them for bulk shipping, product launches, or direct-to-consumer deliveries, our easy fold mailers are lightweight, sturdy, and cost-effective. Choose The Product Boxes UK for premium-quality and custom-branded easy fold mailer boxes.

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Starting From: £0.50 Per Box

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Easy Fold Mailer Boxes– Simple, Safe and Stylish, Shipping Boxes Made Easy

Easy Fold Mailer Boxes are convenient and effective shipping items that have been made to ensure fast assembly and an elegant display. These boxes do not need glue or tape and its rigid material gives products protection during transportation. In addition to the professional and clean image, it increases customer unboxing experience.

We provide tailor-made Mailer Boxes at The Product Boxes UK, which will make your packing experience quicker and superior without losing the durability or the style.

What are Easy Fold Mailer Boxes?

These Boxes are quickly-folded corrugated cardboard boxes that are crafted to assemble with a minimum effort, no glue or tape needed. Designed with both purpose and aesthetics, they provide a safe locking system that holds items securely during transit and a clean premium unboxing experience.

Important Structural Details:

Pre-Creased Panels: Folding lines that are crisp every time.

Self-Locking Flaps: Lock the box in a closed position automatically.

Tuck-in Tabs: Strengthen closure and accidental openings.

Dust Flaps: To cushion against dirt and external factors.

Double-Wall Front Panels: Provide enhanced strength and durability.

Reinforced Side Flaps: Provide extra support and shaping.

Regardless of whether you are shipping tech toys and accessories, beauty products, clothing, or high-end snack foods, these mailers fit your products smoothly.

Constructed Using High-Quality Materials to Meet All Needs

We know that each product should be given a safe ride. We provide several material choices that can fit your branding, protection, and sustainability initiatives:

Corrugated Cardboard (E-flute, B-flute, and others)

The most commonly used shipping and ecommerce package. Corrugated cardboard is a lightweight and extremely stable construction, which makes it exceptionally appropriate in protecting products during shipping.

  • E-flute
  • B-flute:

Kraft Board (Brown or White)

Looking to find sustainable, earthen, minimalistic packaging? The board of choice is the Kraft board.

  • 100% recyclable and biodegradable
  • Eco-friendliness through natural brown finish
  • White Kraft permits clean, high-contrast print finishing

Ideal to fit organic products, handcrafted items and sustainable brands

Premium SBS (Solid Bleached Sulfate)

In case of high-end branding, SBS provides a clear white background that can accommodate bright colours, intricate designs, and luxury finishing.

  • Best suited to direct to customer retail, gifts, and subscription boxes
  • Works well with finishes such as soft-touch coating, foil stamping and spot UV
  • Smooth surface provides a fine, sophisticated touch

Rigid Chipboard (Available on Request)

Rigid chipboard is the solution, when you want your packaging to create a strong feel that lasts.

  • It is a standard in luxury gift boxes and PR kits
  • Introduces a luxury unpacking experience, a solid feel
  • Extremely customisable with magnetic closures, fabric wraps, and others

Reasons to Choose Easy Fold Mailer Boxes Over Other Boxes

Feature Easy Fold Mailer Boxes Standard Mailer Boxes Corrugated Shipping Boxes
Assembly Time Very quick – folds in seconds without tape or glue Moderate – may require flap alignment or light taping Slow – needs full taping and folding
Design Structure Single-piece with locking tabs and dust flaps Tuck-in flaps or two-piece styles Regular slotted carton (RSC) with four flaps
Material Strength Medium – ideal for light to moderate items (E/B flute) Medium – suits small products (E/B flute) High – made for heavier loads (B/C flute)
Best Use Case Subscription boxes, ecommerce orders, light product shipping Cosmetics, clothing, promotional items Bulk items, industrial use, warehouse logistics
Branding Surface Excellent – smooth panels, perfect for digital/offset printing Good – but more folds can disrupt the design Limited – usually plain, branding via stickers or labels
Unboxing Experience Modern and neat – opens cleanly for customer presentation Retail-friendly – decent shelf appeal Basic – purely functional, not for display
Storage Efficiency Highly efficient – ships flat and stacks compactly Flat-packed – saves space in storage Less compact – can take more space
Stackability Good – holds its shape under light stacking Fair – may collapse under pressure Excellent – strong and pallet-ready
Tape/Glue Required No – built-in locking keeps it closed Sometimes – depends on style and closure Yes – requires sealing with tape or glue
Eco-Friendly Options Yes – kraft, recyclable, biodegradable options Yes – recyclable kraft materials available Yes – often made with recycled corrugated board

 

We’ve Custom Sizes That Fit Perfectly To Your Products

We manufacturing custom mailer boxes with inserts to fit your product like a glove, shrinking your shipping cost and increasing protection. It might be a thin tech accessory or a bulky bounce of clothing, we tailor the ideal fit on the size of your product.

Add Inserts, Dividers, Fillers to Keep The Products Organised and Protected

To ensure every item arrives in pristine condition, we offer a range of custom interior solutions:

  • Foam Inserts
  • Cardboard Dividers
  • Die-Cut Inserts
  • Filler Padding

Colour & Finish Options to Make Your Brand Pop

Turn your packaging into a branding tool. With full-colour printing and custom finishes.

  • CMYK & Pantone Printing
  • Gloss & Matte Lamination
  • Soft-Touch Coating
  • Spot UV
  • Foil Stamping (Gold, Silver, Rose Gold)
  • Embossing & Debossing

Whether you want minimal and modern or bold and bright, your packaging will reflect your brand beautifully.

Avail Wholesale Custom Mailer Boxes on Bulk Orders

We specialise in wholesale mailing boxes, meaning you get exceptional quality at scale. Whether you need 500 or 50,000 boxes, our team ensures consistent results, timely delivery, and unbeatable rates.

  • Discounted pricing on volume
  • Consistent print quality
  • Priority production schedules
  • Flexible storage and delivery plans (UK-wide)

Let’s build packaging that performs and impresses only with The Product Boxes UK.

Type Specification
Box Style Easy Fold Mailer with front tuck and dust flaps
Material Options E-flute corrugated, B-flute, kraft board, or SBS paperboard
Material Thickness 1.5mm to 3mm corrugated board, depending on strength needed
Available Sizes Custom dimensions available (standard range: 6x4x2″ to 14x10x4″)
Closure Style Tuck-in front panel with side locking flaps for secure closure
Color Options CMYK full-color, PMS spot colors, kraft brown, or white base
Surface Finish Matte/gloss lamination, soft-touch, aqueous coating, or uncoated
Custom Printing Logo, brand artwork, QR codes, product info, or interior print
Insert Options Optional cardboard, foam, or molded pulp inserts available
Eco-Friendly Options 100% recyclable, FSC-certified kraft, and soy-based inks
MOQ (Minimum Order Quantity) Starts from 100 units (bulk discounts available on higher volumes)
Branding Features Embossing, foil stamping, die-cut windows, and custom shapes
Use Case Subscription kits, e-commerce packaging, product shipments
Shipping Format Delivered flat-packed for space-saving and easy assembly

Q. What makes easy fold mailer boxes different from regular mailers?

A. Easy fold mailer boxes are designed with pre-scored crease lines that simplify the folding process. They allow quick assembly without the need for tape or glue, making them ideal for efficient packaging operations.

Q. Are easy fold mailer boxes strong enough for shipping?

A. Yes, these boxes are typically made from durable corrugated cardboard, providing excellent crush resistance and structural integrity for direct-to-consumer shipping.

Q. What closure options are available for easy fold mailers?

A. Most easy fold mailers come with tuck-in flaps, but they can also be designed with peel-and-seal adhesive strips, locking tabs, or tear strips for added security and convenience during unboxing.

Q. Can I customize the size and depth of easy fold mailer boxes?

A. Yes, these mailers can be fully customized in width, length, and depth to accommodate various product types — from clothing to electronics and subscription kits.

Q. Are easy fold mailer boxes eco-friendly?

A. Most are made from recyclable corrugated material and can be produced using kraft or recycled cardboard. They’re a sustainable option for e-commerce and retail brands.

Q. How much time do easy fold boxes save during packaging?

A. These boxes significantly reduce packing time, especially for high-volume operations. The pre-folded design allows packers to assemble and fill the box in seconds.

Q. Are easy fold mailers suitable for printing and branding?

A. Yes, they offer full exterior print coverage and support techniques like flexo, digital, or offset printing. You can add logos, messaging, or vibrant artwork for brand visibility.

Q. Can these boxes handle heavier items?

A. For heavier products, double-wall corrugated stock or reinforced flaps can be used to increase weight-bearing capacity. Custom inserts may also be added for added internal support.

Q. Do easy fold mailer boxes require additional packaging material inside?

A. It depends on the product. For fragile items, you may need void fill, foam inserts, or molded trays, but for soft goods or boxed products, the mailer alone often provides sufficient protection.

Q. Are easy fold mailers good for subscription box packaging?

A. Absolutely. Their clean design, fast assembly, and printability make them ideal for monthly subscription boxes, gift sets, and influencer mailers.

Related Products

Corrugated

A fluted box material is created to enhance the strength of the boxes for shipment purposes.

Cardboard

Light in weight and easy to print cardstock material that would be molded into any shape and style.

Kraft

Slightly brown paper-like thin material for packaging created by wood pulp and heaving eco-friendly nature.

Rigid

A thick cardboard box that is high in strength but also luxurious in presentation.

Holographic

An impressive as well as laminated paperboard that emulates a 3d look to colors.

Offset Print

High-quality and low-cost printing option that transfers the image to the box surface in a good resolution.

Digital Print

Digital printing techniques do not require any sort of printing plate as it transfers the image to the surface of the box easily without a plate.

UV Print

Safeguard the printed area from fading and make them more attractive.

Pantone

Utilization of a universally accepted color-matching system for printing the boxes.

Hot Foil Stamping

Print the foil detail by using the hot dies on the surface of the packaging boxes.

Cold Foil Stamping

It is a removable foil stamp that is applied without pressing any hot die or pressure on the boxes.

Blind Embossing

Create the raised area on the box surface by applying the pressure, not the inks.

Blind Debossing

Just like the craving on the box created by using letter plates or letter presses.

Registered Embossing

Create both the texture as well as the depth and endow a 3d effect to the area of the box.

Combination Embossing

Both the design as well as foiling is utilised at the same time to create a more appealing presentation.

Window Patching

Create a plain see-through cut in the box that is covered with a see-through plastic sheet.

Aqueous Coating

Provide tear-free impact to the packaging with a clear and fast-drying water-based coating at the time of printing.

UV Coating

Add protection against the damaging impact of UV sun rays by applying the UV coating to the packaging.

Spot Gloss UV

Annex the glossy effect on the specific areas of the packaging through spot coating.

Soft Touch Coating

Use the soft touch coating to make the darker and dull areas of the packaging velvety and smooth.

Varnish

Provides protection as well as perfect presentation to the printing part of boxes.

Lamination

A very thin plastic film is pasted in the boxes to make them more durable and long-lasting.

Anti-Scratch Lamination

This thin film of plastic is used to endow the scuff as well as scratch resistance to the boxes.
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