Three structures account for most of the custom boxes we make: mailer boxes, shipping boxes and folding cartons. They look similar on a website, but they are built differently, cost differently and suit different jobs. Here is how to choose.
Quick comparison
| Mailer box | Shipping box (RSC) | Folding carton | |
|---|---|---|---|
| Material | E-flute or B-flute corrugated | B, C or BC corrugated | SBS or kraft paperboard |
| Closure | Self-locking tabs, no tape | Flaps taped shut | Tuck ends or glued bottom |
| Ships alone? | Yes | Yes | No, needs an outer box |
| Print quality | Very good, full colour inside and out | Good, usually 1 to 2 colours | Excellent, highest resolution |
| Typical cost at 1,000 | $0.90 to $1.60 | $1.20 to $2.40 | $0.35 to $0.80 |
| Best for | E-commerce, subscription, gifting | Bulk shipping, heavy goods | Retail shelf, cosmetics, food |
Mailer boxes
A mailer box is a corrugated box that folds into shape and locks with its own tabs. The roll-end tuck-front (RETF) style is the most common: the lid rolls over the front and tucks in, and the side walls are double thickness for strength.
Choose a mailer when the box goes directly to the customer and the unboxing matters. Mailers print beautifully on both sides, close without tape and photograph well. They are the default for subscription boxes, DTC apparel, cosmetics sets and gift kits.
Watch out for size. Mailers are efficient up to about 14 x 11 x 5 in. Larger than that, the lid loses rigidity and a shipping box becomes cheaper and stronger.
Shipping boxes (RSC)
The regular slotted container is the brown box everyone knows. Four flaps meet in the middle on top and bottom and are taped shut. It uses the least board for a given volume, which makes it the cheapest way to move goods.
Choose a shipping box when you need to move weight or volume, when the box will be stacked on a pallet, or when it is an outer carton around retail packaging. Custom printing one or two colours on kraft is inexpensive and looks intentional.
Watch out for the unboxing. A taped RSC never feels premium. If it goes to the end customer, consider a printed mailer or at least custom tape and tissue.
Folding cartons
A folding carton is a single piece of paperboard, die-cut and glued, that folds into a box. Straight tuck end, reverse tuck end, auto-lock bottom and seal-end are all folding cartons. They are what you see on retail shelves: cosmetics, supplements, tea, toys, electronics accessories.
Choose a folding carton when the product sits on a shelf or inside another box. Paperboard takes the finest print, foil, embossing and windows, and it is the most economical format per unit.
Watch out for shipping. Paperboard is not strong enough to ship on its own. Plan a mailer or RSC outer.
A decision checklist
- Does the box ship alone to a customer? Mailer (premium) or RSC (bulk).
- Does it sit on a retail shelf? Folding carton, possibly with a window.
- Is the product heavier than about 5 lb? B-flute mailer or RSC; skip paperboard.
- Does unboxing drive social sharing? Mailer with inside print.
- Is unit cost the priority? Folding carton for retail, RSC for shipping.
Many brands use two: a folding carton for the product and a mailer or RSC to ship it. Ordering both from one manufacturer keeps colours consistent and simplifies logistics.
Still unsure?
Send us the product dimensions and weight through the quote form. Our structural engineers recommend the lightest structure that protects it, free, with a dieline you can review before ordering.