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When it comes to shipping, choosing the right box is more than just fitting a product inside; it’s about protecting your bottom line and your brand’s reputation.
Whether you are a startup online seller or a high-volume e-commerce giant, the debate of mailer boxes vs shipping boxes is one you will eventually face. Choosing the wrong one can either lead to damaged goods or high shipping costs.
In this post, we will break down the differences between the two to help you make the right choice for your budget and your customers.
What are Mailer Boxes?
Mailer boxes are stylish, one-piece containers designed to store and ship products without adhesive tape to keep them closed. They feature “wings” and interlocking flaps that “snap” into place, creating a double-walled side for extra durability. Besides e-commerce shipping, these boxes are also the gold standard for subscription or PR boxes and high-end retail packaging.
What are Shipping Boxes?
Shipping boxes are the classic brown boxes you see on every doorstep. They are built for utility and strength. These boxes come in four flaps on the top and bottom that meet in the center and must be sealed with heavy-duty packing tape.
Difference Between Mailer Boxes and Shipping Boxes
Both are ideal for shipping, right? So, what’s the difference between mailer boxes vs shipping boxes? The main difference is that a mailer box focuses on the experience, while a shipping box focuses more on endurance.
Let’s have a look at the differences in detail.
Materials
The material used determines how much weight a box can hold and how well it prints.
- Mailer Boxes
Usually made from E-flute or B-flute corrugated. These are thinner (about 1/16″ to 1/8″), providing a smooth surface that is perfect for high-quality, full-color printing. In addition, kraft paper is an excellent, sustainable material for producing sturdy and eco-friendly mailer boxes.
- Shipping Boxes
Typically made from thicker C-flute or even double-walled corrugated. This adds a “cushion” of air between the layers. Hence, they are much more resistant to punctures and stacking pressure in a crowded delivery truck.
Types
Just like other custom boxes, there are different types of mailer boxes and shipping boxes you can choose from.
Mailer Boxes
Designed for speed and style, mailer boxes come in a few specific configurations.
- Roll End Tuck Top (RETT): The most popular style with the front flap tucks into the main body, and the side flaps fold in to create reinforced walls.
- Dust Flaps: These are small extra flaps on the sides of the lid that prevent dirt, dust, and debris from entering the box during transit.
- Self-Locking: Feature an “ear” or tab mechanism that locks the box shut, ensuring it doesn’t pop open without messy tape.
Shipping Boxes
Shipping boxes are the workhorses of the logistics world, categorized by their structural integrity.
- Corrugated Boxes: The broad term for any box with a “fluted” layer. They provide excellent insulation and shock absorption.
- Regular Slotted Container (RSC): The container features flaps of equal length, and the outer flaps meet in the middle. It’s the most cost-effective box to produce.
- Flat Boxes: These are shallow boxes designed for items such as mirrors, artwork, or clothing that need to remain flat to prevent shifting.
- Die Cut Boxes: Custom-shaped boxes designed to fit a specific, uniquely shaped product perfectly, reducing the need for “void fill” such as bubble wrap.
Assembling
A mailer box requires a bit of paper folding but no tape. Meanwhile, a shipping box pops open faster but requires taping both the bottom and the top.
Printing
When it comes to printing, mailer boxes are the winners here. They offer a “canvas” for interior and exterior printing. You can even polish the boxes with specialty finishes like spot UV, foil stamping, or matte/gloss lamination. Plus, you can get your brand logo embossed or debossed on them.
And shipping boxes? They usually kept plain or used with simple one-color logos.
Reusability
A customized mailer box with attractive colors and designs is loved by customers. Many even reuse the box for storage because it opens and closes easily. On the other hand, a shipping box is usually broken down and recycled immediately.
Flexibility
In terms of flexibility, shipping boxes excel because they can safely hold and ship almost all products. And mailer boxes are mostly chosen for shipping lightweight products like apparel, cosmetics, or gift items.
Storage
Both ship flat. However, because mailer boxes are thinner, you can often fit more of them on a single pallet than thick corrugated shipping boxes.
Ideal Products
Mailer boxes work well for jewelry, electronics, and lightweight apparel. Meanwhile, shipping boxes are meant for heavy tools, bulk orders, or kitchen appliances.
Cost
Speaking of cost, you can get shipping boxes at a lower per-unit price. But mailer boxes carry a premium price due to the complex die-cutting process and customization.
Mailer Boxes vs Shipping Boxes: Quick Comparison Table
| Feature | Mailer Boxes | Shipping Boxes |
|---|---|---|
| Materials | E-flute or B-flute corrugated, kraft paper | C-flute or double-walled corrugated |
| Types | RETT, Dust Flaps, Self-Locking | Corrugated Boxes, RSC, Flat Boxes, Die Cut Boxes |
| Assembling | Folding without paper tape | Require tapes on the top and bottom |
| Printing | Interior & exterior printing | Plain, one-color logos |
| Reusability | High | Low |
| Flexibility | Moderate | High |
| Storage | Ship flat | Ship flat |
| Ideal Products | Lightweight, semi-fragile products | Heavy, fragile, bulky products |
| Cost | High | Low |
When to Use Mailer Boxes vs Shipping Boxes
Now let’s get to the main point: When to use mailer boxes and when to use shipping boxes?
When choosing between the two, you must consider some essential factors.
What are they?
Product Weight & Size
If your product is over 10 lbs, a shipping box is safer. For lightweight items, a mailer box is more than sufficient.
Also, you need to consider the right box dimensions for shipping. After all, to get your shipping costs right and avoid shipping “air” fees, you need to be precise.
Fragility & Protection
Shipping boxes offer superior stacking strength, making them ideal for safely shipping glass items. Mailer boxes also offer a protective shield, but for semi-fragile items like cosmetic bottles or curated gift sets.
Another thing you must learn is how to choose between 200# and 32 ECT boxes for shipping. In brief, 200# boxes are marked for burst strength, while 32 ECT boxes are famous for stacking strength.
Branding & Unboxing Experience
As we mentioned above, a shipping box is meant for shipping. That’s why it typically comes as a simple, plain brown box. If your marketing strategy relies on “Instagrammable” unboxing moments, choose a mailer box. The way it opens like a chest feels like a gift, and its smooth surface serves as your branding canvas—all the reasons to choose mailer boxes.
Assembly & Storage
If you have limited space, mailer boxes are thinner and take up less room. However, if you are packing hundreds of items an hour, the simple “tape and go” of an RSC shipping box might be faster for your team.
Cost Efficiency
Most carriers use automated scanners that catch even a fraction of an inch of “bump” in a box. And we should also mention DIM (Dimensional Weight), a pricing method carriers use to compensate them for the space a package occupies, not just its actual weight.
Speaking of cost efficiency, a mailer box is often more compact, which can actually save you money on shipping fees even if the box itself costs more.
The Verdict
Choose mailer boxes when:
- You want a premium, branded unboxing experience.
- Your items are lightweight or medium-weight.
- You want to eliminate the use of plastic packing tape.
Choose shipping boxes when:
- You are shipping heavy, bulky, or fragile items.
- You are looking for the lowest possible cost per box.
- You are shipping bulk products to a warehouse or retail store.
Final Thoughts
Undoubtedly, when it comes to shipping, choosing the right box is about protecting your bottom line and your brand’s reputation. The main difference is that a mailer box focuses on the experience, while a shipping box focuses more on endurance.
Choose mailer boxes for lightweight products and delivering a premium experience. And choose shipping boxes if you are shipping heavy, bulky products and want to keep your budget in check.
FAQs
What are mailer boxes?
Mailer boxes are stylish, one-piece containers designed to store and ship products without adhesive tape to keep them closed.
What are shipping boxes?
Shipping boxes come in four flaps on the top and bottom that meet in the center and must be sealed with heavy-duty packing tape.
What’s the difference between mailer boxes vs shipping boxes?
The main difference is that a mailer box focuses on the experience, while a shipping box focuses more on endurance.
What products are ideal to ship in mailer boxes and which in shipping boxes?
Mailer boxes are ideal for shipping lightweight products, while shipping boxes are perfect for shipping heavy, bulky products.
