How to Choose Corrugated Mailer Boxes: 5 Key Factors [2024]

The first step in selecting a corrugated mailer box is to determine the dimensions which must include the length, width and height of your product. Any box larger than the product will have a cushion, which will allow the product to shuffle and cause scratches and damage. On the other hand, a box smaller than the product will crush the item and will be harder to seal. The ideal dimension is to first measure your product and add one or two inches to every dimension. This will give enough space to add extra bubble wrap or packing peanuts, without bulging the box. For example, a product 8 inches long 5 inches wide and 3 inches tall will fit a box with dimensions 9 to 10 inches length, 6 to 7 inches width and 4 to 5 inches height. These dimensions are perfect to ensure the product is safely transported and excess packaging is not used.

Fragility and Weight of the Product

As the weight and fragility of the product increases, the strength you need for the mailer box will be stronger. mailer boxes are measure based on burst strength and edge crush test. The higher the value, the stronger the box.

A standard single wall cardboard box (with ECT rating of 32) is sufficient for lightweight and non fragile items such as clothing and books. For heavier items such as small electronics and glassware, a double wall cardboard box (ECT rating of 44 or higher) is preferable as it withstands more pressure and impact. Box a box as selected to fragile products such as ceramics and delicate instruments requires more protection. In such a case choose a box with thicker flutes (the wavy layer inside the corrugated material) such as B flutes or C flutes which absorb shocks better during shipping. Box failure and product damage are results of ignoring weight and fragility. Therefore, such factors should never be overlooked.

Selecting the Specific Box Style for Your Requirements

Different styles of corrugated mailer boxes are available and each is designed for specific functions. The most common is the regular slotted container (RSC) style which features flaps that fold over and seal at the top and bottom. This style is most suitable for general products. For products requiring quick and easy access, such as subscription boxes or gift sets, a mailer box with a tuck top or flip top lid is more practical as it enables the customer to open the box without tearing it.

When Shipping rolled items like posters, fabric. A Telescoping box (which has two parts that slide together) offers better protection. For fragile items that need to be secured. A more secure option like a die cut mailer box with foam or custom cardboard dividers stops any movement. Selecting a box also increases satisfaction.

Consider the moisture, dust, and temperature control to verify the box is sealed properly. During shipments, these are two important factors to consider. For items that are sensitive to moisture like, paper, or leather. Opting for boxes that repel moisture will keep the box sturdy. A box with a smooth surface is better to be used in dusty environments for easy cleaning.

For items that need to be stored in extreme conditions (like foods or medicines), use boxes crafted with heat or cold resistant corrugated material. This will ensure the box preserves its structural integrity and safeguards the item, no matter the conditions.

Explore Customization Options for Purposes of Branding and or Functionality

Customization of your corrugated mailer box can assist with branding and improve its practicality. Many companies place their logo, primary colors, or tagline on the box. This helps to create brand visibility in addition to making the box more attractive to the consumers. Customization can also include practicality, like pre-printed labels for return addresses and specific handling instructions. This helps to minimize wasted time as well as tagging mistakes. For other items that fall under sensitive handling, such as perishables, one can include more emphatic instructions outside the box with tell-tale phrases or symbols like, ‘Keep Refrigerated!’ This warns all shipping associates to be extra careful with the box. On top of all this, the mailer box can also accommodate custom, added partitions to separate different products. This also provides added protection to the items in the mailer box. Customization improves the performance of the corrugated mailer box to suit your brand requirements.

Assess Monetary value versus Sustainable Practices

As for cost and sustainability editions, border on practicality of the corrugated mailer box.

Replacements and product damage can spiral if low quality boxes of the cheapest price are selected first. This will make them far more costly in the long run. Select a box of reasonable quality and price instead. It should sufficiently protect the product while keeping the price reasonable. The box should also be sustainable and composed of recycled corrugated material since they are eco-friendly and appeal to conservative customers. Also, try to identify boxes that are simple to recycle post use and those without attachments and coatings that are non-recyclable. Biodegradable corrugated boxes are also a great selections since they are designed to naturally breakdown over a period of time. Also, evaluating cost and sustainability will help you stay true to the brand while saving money in the process.