FEFCO 0427 AND CUSTOM SOLUTIONS
Mailer boxes that protect and present
Mailer boxes suit small consignments, samples, spare parts and products delivered directly to the customer. The stable structure protects in transit while providing a clean surface for branding, product information and campaign messages.
One of the most common structures is FEFCO 0427. It is supplied flat, erected quickly and encloses the product with double side walls and a close-fitting lid. The basic structure closes without separate tape.
Structure, closure and protection
Closure and returns
FEFCO 0427 normally locks with folded tabs. It can be equipped with a self-adhesive closure, a tear strip for easy opening and a second adhesive strip for return shipments.
Protective inserts
Fit can be improved with integrated inserts, dividers, locks or cushioning parts. The product stays in position and the need for loose void fill can be reduced.
Letterbox or parcel flow
A box intended for letterbox delivery should be no more than 30 mm deep. Always verify the carrier’s current size, weight and sorting requirements before finalising the structure.
For products delivered directly to the recipient
Mailer boxes are used for books, printed material, electronics, small industrial components, cosmetics, samples, games and gift products. They work in postal, parcel, e-commerce and courier distribution.
Both lid and base can be printed, making the box suitable for products that need visual presentation. A considered opening experience carries the brand all the way to the recipient.
- Small consignments and product samples
- Direct customer deliveries
- E-commerce and subscription shipments
- Spare parts and industrial components
- Books, games and printed products
- Cosmetics and gift products
Standard size or custom mailer box?
Quickly from the standard range
Use Fitbox to search a selection of our standard sizes. A stock box is a good choice when its dimensions suit both the product and carrier pricing.
Optimised for the product
Most mailer boxes are made to measure. Correct internal dimensions reduce empty space, material use and shipping volume. Check carrier size and weight limits early – a few millimetres can affect cost and sorting class.
Material, printing and recycling
Material is engineered for product weight, sensitivity and distribution method – not only the outer dimensions of the box.
F-, E- or B-flute
Mailer boxes are mainly made from thin F-, E- or B-flute corrugated board. Finer profiles provide a compact, print-friendly result, while a stronger grade is selected when the product or journey needs more protection.
All our printing methods
We offer offset, flexographic and digital printing according to artwork, volume, material and quality requirements. The inside can also be printed with instructions or for a stronger unboxing experience.
Fibre-based recycling
A box without unnecessary material combinations can be sorted as carton or corrugated board under local guidance. Integrated board inserts can also replace some plastic and loose void fill.
Optimise material, shipping volume and packing time
- 01
Size for the product
Less empty space reduces material use and improves transport efficiency.
- 02
Match the distribution chain
We consider letterboxes, parcel lockers, terminal handling, pallets and carrier price thresholds.
- 03
Plan the packing process
Folding order, locks, adhesive strips and assembly aids are adapted to volume and packing flow.
- 04
Test before production
A sample verifies fit, protection, opening and packing time.
FREQUENTLY ASKED QUESTIONS
Questions about mailer boxes
What is the minimum order?
The minimum depends on structure, material, printing method and size. We can also produce small trial runs. Include the expected volume in your quote request and we will recommend an economical approach.
Can I receive a sample?
Yes. For a custom solution we can make an unprinted structural sample to check dimensions and function. Printed samples and short trial runs are assessed case by case.
What is the lead time?
Lead time depends on structure, material availability, print, finishing and quantity. Standard sizes can often be delivered sooner. An estimated schedule is provided with the quotation.
Can the box be used for returns?
Yes. We can design it for easy opening and add a second self-adhesive strip so that the same package can be resealed for return.
Can you adapt the box to a letterbox or parcel locker?
Yes. We work from the product dimensions and the chosen distribution channel’s requirements. A letterbox pack should be no more than 30 mm deep; other channels have their own limits.
Which printing method is best?
Offset gives very high image and colour quality, flexo is efficient for simpler artwork and larger volumes, and digital printing suits shorter runs or variable content. We recommend the method for each project.