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Our durable and stylish custom mailer boxes are a top choice in the eCommerce industry! Keep your products secure while delivering them to customers with elegance. Ideal for retail packaging, subscription boxes, and gift boxes, they offer both protection and a premium unboxing experience.
Packaging inserts and inlays help keep your products secure and well-organized. Customize your paper or cardboard inserts with full-color printing and designs that seamlessly complement your packaging.
Custom box inserts are designed to fit your products perfectly, ensuring they stay secure during transit while enhancing the unboxing experience for your customers. For delicate items, foam inserts provide extra protection and cushioning.
Paper and cardboard box inserts are produced using offset printing, delivering crisp, vibrant results at a budget-friendly cost.
Beyond protecting your products, custom inserts enhance their presentation during the unboxing experience. When packaging multiple items in one box, inserts help arrange each product perfectly to your preference. Take inspiration from how brands use custom box inserts to create memorable brand experiences.
With custom box inserts, a one-size-fits-all approach doesn’t work. Each insert is specifically designed to fit the size, weight, and placement of your products, ensuring maximum protection. Here are some common paper and cardboard insert structures:
Box Insert (No Backing): Ideal for products that sit directly at the bottom of the box without needing elevation. This type works well for items of the same size.
Box Insert (With Backing): Designed for products of similar sizes that require elevation for a secure fit or need additional support.
Our expert team will guide you through the structural design process to determine the best insert solution for your products.
An overview of the standard customizations available for custom box inserts
Corrugated box inserts, featuring the characteristic wavy layers in cardboard, provide enhanced strength and durability. These sturdy inserts are ideal for heavier or fragile items, offering extra cushioning and protection during shipping. Designs are printed on these base materials and then adhered to the corrugated board. Each material is made with at least 50% post-consumer recycled content.
Most commonly used option and has a flute thickness of 1.2-2mm.
Ideal for large boxes and heavy items, with a flute thickness of 2.5-3mm.
Clay Coated News Back (CCNB) paper that’s most ideal for printed corrugated solutions.
Unbleached brown paper that is ideal for only black or white print.
Paper-based box inserts, without corrugation, are best suited for lightweight, non-fragile items. These inserts typically have a standard thickness of 300-400gsm and are made with at least 50% post-consumer recycled content.
Foam packaging inserts are crafted to ensure products remain safe and secure during transit. Fully customizable, they offer a precise fit that safeguards fragile or delicate items from potential damage.
Solid Bleached Sulfate (SBS) paper that yields high quality print.
Unbleached brown paper that is ideal for only black or white print.
Open-cell Polyurethane foam is softer and more flexible, resembling the material of a sponge. Available in black or white.
Closed-cell Ethylene Vinyl Acetate foam is more rigid and dense than open cell foam, resembling the material of a yoga mat. Available in black or white.
All packaging is printed using soy-based ink, an eco-friendly option that enhances color vibrancy and brightness.
CMYK is the most popular and cost effective color system used in print.
For accurate brand colors to be printed and is more expensive than CMYK.
A protective coating is applied to your printed designs to prevent scratches and scuffs.
An eco-friendly water-based coating but doesn’t protect as well as lamination.
A plastic coated layer that protects your designs from cracks and tears, but not eco-friendly.
Enhance your packaging with a finishing option that adds the perfect final touch.
Smooth and non-reflective, overall softer look.
Shiny and reflective, more prone to fingerprints.
Semi-shiny, in between a matte and glossy look.
Looks like a matte finish, but feels like velvet.