Packaging Solutions · Mailer Boxes
Custom Mailer Boxes in Delhi NCR
RoboSouls supplies custom printed corrugated mailer boxes to e-commerce and D2C brands in Delhi NCR, self-locking, with printing inside and out and optional insert trays. Dielines and all finishing are done in-house at the RoboSouls production unit in Naraina, New Delhi. Mailers are quoted per job and delivered across India.
Mailer boxes are the flagship of e-commerce packaging and subscription brands. Self-locking, corrugated for protection, and fully printable inside and out — they turn delivery into a brand moment. We engineer them to arrive flat-packed and pristine.
Available variants
Specifications
- MOQ
- Quoted per job
- Material
- 3-ply / 5-ply Corrugated Board
- Exterior Print
- Full-colour offset or flexo
- Interior Print
- Full-colour available
- Finish
- Matte, Gloss Lamination, Kraft Natural
- Lead Time
- Confirmed at quotation
1. What a mailer box is
A mailer box is a die-cut corrugated box that folds into shape with a tuck-in lid and side flaps that lock without tape or glue. Corrugated board has a fluted layer between two liners, which gives it the crush strength to survive courier sorting and delivery on its own. For D2C and e-commerce brands the mailer is both the shipping carton and the first thing the customer opens.
2. Corrugated board and flutes
Corrugated board is described by its walls and its flute. Single-wall board (3-ply) has one fluted layer and suits most products; double-wall (5-ply) has two and suits heavier or more fragile goods. Finer flutes give a smoother surface for print and a slimmer box; larger flutes give more cushioning. The board is chosen for the product's weight and fragility and is confirmed when RoboSouls quotes.
3. Sizing for the courier
Couriers charge by whichever is greater, actual weight or volumetric weight, so a mailer that is larger than it needs to be costs money on every parcel. Size the box to the product plus its insert, with only the allowance it needs. RoboSouls creates the dieline in-house to the product's dimensions, which is what keeps empty space and fill to a minimum.
4. Printing inside and out
A mailer can be printed on the outside, the inside, or both. Printing the inside means the lid opens onto the brand, which is the moment customers notice most. Finishing, including lamination, foil stamping, embossing, debossing and UV coating, is done in-house. Insert trays hold the product and any leaflet or card in place.
5. Who uses mailer boxes
D2C and e-commerce brands shipping single orders, subscription boxes, and brands sending launch packages to customers. A premium product often goes inside the mailer in its own mono carton or rigid box, with the mailer doing the protecting. RoboSouls supplies mailer boxes to brands across India from Naraina, New Delhi. The minimum quantity and lead time are confirmed when RoboSouls quotes, and payment is 50 percent in advance and 50 percent on delivery.
6. Questions about mailer boxes
What is the difference between a mailer box and a shipping carton?
A mailer box is a die-cut corrugated box with a tuck-in lid, made to ship one order and to be opened by the customer. A plain shipping carton is taped shut and usually carries several products.
Should I choose 3-ply or 5-ply corrugated for mailer boxes?
3-ply (single wall) suits most products. 5-ply (double wall) suits heavier or more fragile products. The board is chosen for the product's weight and confirmed when RoboSouls quotes.
Can mailer boxes be printed on the inside?
Yes. Mailers can be printed outside, inside or both. Inside print means the lid opens onto the brand.
What is the minimum order quantity for mailer boxes?
It depends on the format, size and finishing, because setup work is the same whatever the run length. RoboSouls confirms the minimum for your job when it quotes. Share the format and the quantity you need.
Which formats and finishes are available for mailer boxes?
Formats include Standard Mailer, Full-Colour Exterior, Interior Printed, With Insert Tray, E-Commerce Friendly (no tape needed), Corrugated Single Wall. All finishing is done in-house: foil stamping, embossing, debossing, UV coating and soft-touch lamination, which can be combined on one job.
Can RoboSouls design the artwork and the dieline?
Yes. Custom design, artwork adaptation and dieline creation are done in-house. If you supply your own dieline, it is checked for production before printing.
What is the lead time for mailer boxes?
Lead time depends on quantity and finishing and is confirmed when RoboSouls quotes. Rush jobs are possible in some cases and handled case by case, so share your deadline with the brief.
Can I get a sample before the full order?
Yes. Whether a sample is free or paid depends on the job, and RoboSouls tells you which when it quotes.
Do you deliver mailer boxes outside Delhi NCR?
Yes. RoboSouls produces in Naraina, New Delhi, and delivers across India. Payment terms are 50 percent in advance and 50 percent on delivery.
