Cosmetic mailer box
E-flute with paperboard insert200 minimum · 10 to 14 business daysA cosmetic mailer box is an E-flute corrugated mailer with a fitted 24pt paperboard insert that holds jars, droppers and tubes upright so glass does not meet glass. We print the box inside and out and the insert to match, from 200 units in 10 to 14 business days after proof. Common sizes are 8 by 6 by 3 and 10 by 8 by 3 inches.
When to choose it, and when not to
Choose a cosmetic mailer when glass or a pump travels in the mail. A 2 oz jar, a 30 ml dropper and a 50 ml tube in one box will rattle without an insert and one of them will leak by week three. A die-cut cradle with a cavity per item holds each one upright and gives the box a shelf-like order when it opens. Skincare sets, launch kits, PR seeding and sample boxes for a subscription tier all use this build. Soft-touch on the outside suits the category.
Choose a skincare set box in rigid board when the set is a gift or a retail item and the box will be kept, since a mailer is built to ship. Choose a kraft mailer with tissue for a single tube or balm, because a full insert for one soft item is money spent on air.
Specifications
| Board | E-flute corrugated, white top liner, 32 ECT |
|---|---|
| Full color digital or litho laminated, inside and out | |
| Finish | Matte aqueous, soft-touch lamination or spot gloss |
| Closure | Tuck-in lid with side locking tabs, tear strip optional |
| Insert | Die-cut 24pt SBS or E-flute cradle, printed or plain, 1 to 6 cavities |
| Cavity fit | Cut to your jar or bottle diameter plus 0.08 in |
| Minimum | 200 units |
| Lead time | 10 to 14 business days after proof |
| Ships | Flat, inserts bundled separately |
| Sizes we run | 6 x 6 x 3 in 8 x 6 x 3 in 9 x 7 x 3 in 10 x 8 x 3 in 12 x 9 x 4 in any size from 5 x 5 x 2 to 16 x 12 x 6 in |
Materials that suit it
Questions people ask
How does the insert hold a jar upright?
A die-cut 24pt SBS sheet with a cavity cut to the jar diameter plus 0.08 in, folded to stand about 1 inch above the floor of the box. The jar drops in and the collar stops it tipping. Heavier glass over 4 oz gets a two-layer insert or an E-flute cradle for more grip.
Will the insert work with different bottle sizes?
Only if it is cut for them. Send the diameter and height of each item, or a photo beside a coin, and we spec one cavity per item. A set of three products needs three cavities. If your range changes, a new insert die is a small change and the box stays the same.
Is soft-touch worth it on a shipping box?
For cosmetics, usually. The velvet feel is the first thing a customer notices and it hides light scuffs. It adds about 3 business days to the lead time. If the box goes inside an outer shipper, matte aqueous does the job for less.
Can the insert be printed?
Yes. The insert prints full color on one side, the side that faces up, so it can carry product names beside each cavity or a color that matches the inside lid. Plain white or kraft insert board is also fine and is one less proof to check.
What clearance should the box have?
Half an inch above the tallest item so the lid closes without pressing on a pump, and the insert cavity at product diameter plus 0.08 in. Too loose and the jar tips; too tight and it is hard to lift out. We check this on the digital proof against your dimensions.
How is the cosmetic mailer box different from cosmetic packaging boxes?
The mailer ships; the carton sits on a shelf. The cosmetic mailer box is 32 ECT E-flute corrugated with a die-cut 24pt SBS or E-flute insert holding one to six jars, droppers or tubes, printed inside and out, so a set goes straight to a customer without an outer box. Cosmetic packaging boxes are single-product folding cartons on 16 to 24pt SBS for retail shelves or to ride inside a shipper. Both start at 200 units in 10 to 14 business days after proof. Sets, PR seeding and direct-to-customer orders go in the mailer.
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Ready to price your cosmetic mailer box?
Send the size and quantity for a quote and a dieline, usually within one business day. Your digital proof follows, usually within one business day of your artwork. Design help and the Swatch Book of materials are free.