How to Choose the Perfect Mailer Box Size for Your Needs?

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    When shipping any product, you might come across two options: a mailer box and a shipping box. Of course, each comes with its unique characteristics and features. However, a custom mailer box today ends up getting more popular. Accordingly, many brands prefer to ship their products in an exclusive mailer box. However, you need the right box size to ship your products safely. How about choosing the perfect mailer box size for your needs? Let’s discuss this further!


    What Is the Purpose of a Mailer Box?

    Before we dive into the accurate mailer box dimensions, let’s know more about this box.

    So, a mailer box is a type of packaging designed to store and send products safely. One of the main benefits of using this box is that it is easy to assemble. Yes, it means you require no adhesive tape to assemble and close the box.

    Moreover, a mailer box comes with double side walls. This structure makes the box durable. In addition, mailer boxes usually come white on the inside and brown on the outside. Furthermore, the top and bottom of the box are flat, while the sides are sloped. No doubt, this design allows for easy stacking and storage. Even better, it will be more resistant to help you ship your products safely.

    What’s more, mailer boxes are ideal for flat or thin, lightweight products. For example, you can ship apparel, books, picture frames, wallets, sunglasses, cosmetics, and jewelry. Most importantly, these boxes are also a popular choice to add branding, flexibility, and extra protection to your products.

    So, if you want to choose the correct mailer box size dimensions, you need to measure the dimensions of your product. You can do this easily by measuring your product’s length, width, and height. Remember, the bigger your product, the larger the mailer box you should get.

    The Differences Between Mailer Boxes and Shipping Boxes

    In brief, mailers and shipping boxes are best for shipping products.

    However, there are some differences between the two!

    • Material

    Shipping boxes are made from thicker materials such as corrugated. Meanwhile, mailer boxes are made from thinner materials like paperboard.

    • Shape

    Shipping boxes typically come in a rectangular or square shape. Meanwhile, mailer boxes have a flatter shape along with sloping sides.

    • Size

    Shipping boxes are typically larger. On the other hand, mailer boxes are smaller and perfect for flat or thin products.

    • Customizability

    Without any doubt, mailer boxes are more customizable than shipping boxes.

    • Cost

    Their smaller size and lighter weight make mailer boxes cheaper than shipping boxes.

    Why Do You Need the Right Box Dimensions?

    Well, we know that every product has its size and volume. So, when it comes to shipping any product, you need to choose the right packaging according to your product. Most importantly, the appropriate dimensions of a box will keep your product safe and sound.

    Simply put, choosing the right mailer dimensions is essential. By having the box at the accurate size, you can ensure your product will arrive perfectly at your customers’ doorstep.

    After all, a mailer box that is too small will not be able to fit your product. On the other hand, a mailer box that is too large can cause your product to move around inside the packaging. Hence, leading to damage during shipping.

    Typically, the rule of thumb for mailer boxes is that the dimensions should be big enough. This way, your product can fit and be secure inside the box. Most importantly, your product should be snug inside the box. Thus, using an oversized mailer box is not a good idea.

    By using a mailer box that’s sized appropriately relative to the size of your product, you can:

    • Prevent your product from moving around inside the packaging
    • Avoid damage to your product
    • Evade using too much void fill or eliminating its use entirely

    Once you have measured your product’s dimensions, you can consider different Mailer sizes.

    Here’s the scoop:

    • Small mailer boxes are ideal for lightweight products such as jewelry, accessories, candles, and similarly sized products
    • Medium mailer boxes are versatile and can accommodate a wide range of products, such as clothes, bags, small appliances, and even shoes
    • Large mailer boxes are large enough to fit hefty kitchen appliances for example microwave ovens or high-end electronics like televisions

    What Factors Influence the Mailer Standard Size We Need?


    Of course, the standard size of a mailer box can vary depending on your intended use. Moreover, the size of a mailer box depends on some important factors.

    What are they?

    Type of Product

    The type of product you need to ship will surely influence the decision of the size of your box.

    For example, flat products like shirts or blouses surely require a different box size than large products like shoes.

    Product Dimensions

    The product size you want to ship is another important factor in determining the size of your mailer box. So, ensure you measure your product’s length, width, and height. Also, remember that your box should be big enough to fit and secure your product inside. Of course, without leaving too much empty space.

    Shipping Method

    Definitely, the shipping method you choose can also affect the dimensions of the paper box you need. For example, if you’re shipping via USPS, you must ensure that your box meets their size requirements.

    Void Fill

    In case you need to use void fill to protect your product during shipping, this will affect the size of your box. Yes, you need to ensure your box has enough space to accommodate any void fill you plan to use.

    Brand Image

    Yes, your brand image can also influence the size of your mailer box. A larger box can provide more space for branding and marketing messages. On the other hand, a smaller box can be more cost-effective and eco-friendly.

    Considering these factors, you can choose the typical mailer size you need. Better yet, you can ensure your products arrive safely and securely.

    To help you get the accurate size for your mailer box, look at the mailer sizes chart below!

    Product’s Weight (in grams)


    Product’s Weight (in grams) Interior Exterior: Flap Open Exterior: Flap closed
    15 6 x 9 inches 7 x 11.125 inches 7 x 9 inches
    27 11 x 9 inches 12 x 11.125 inches 11 x 9 inches
    30 13 x 9 inches 14 x 11.125 inches 13 x 9 inches
    42 11 x 15 inches 12 x 17.125 inches 11 x 15 inches
    56 13 x 18 inches 14 x 20.125 inches 13 x 18 inches


    How to Measure the Average Mailer Size for Shipping?

    To measure the right size for your mailer boxes, you need to consider the dimensions of the product you’re shipping.

    Here are some steps to follow!

    • Measure the length, width, and height of your product using a ruler or tape measure
    • Choose a mailer box that is slightly larger than your product
    • Ensure that the box is not too large, as this can increase shipping costs and leave your product vulnerable to damage during transit
    • Consider the type of product you’re shipping
    • Choose a mailer box that is appropriate for your product’s size and shape

    If you need to ship multiple products, consider using a larger mailer box instead of multiple smaller mailer boxes.

    How about poly mailer measurements?

    If you want to use a poly mailer, you can measure a poly mailer with these steps:

    • Measure the length, width, and height of the product you want to ship
    • Add 1/4 inch to the product height twice
    • Add the product length to get the minimum poly mailer length
    • Now, add 1/4 inch to the product height
    • Then, add the product width to get the minimum poly mailer width

    For example, suppose your product has a length of 10 inches, a width of 8 inches, and a height of 2 inches. Then, you should measure the minimum poly mailer length in 25.5 inches (10 + 2 + 2 + 0.25 + 0.25), and the minimum poly mailer width should be 11.5 inches (8 + 2 + 0.25).

    The Benefits of Shipping Products with Mailer Boxes

    There are several benefits to shipping products with innovative mailer boxes.

    Check out some of the most promising benefits you can get below!

    Excellent Product Protection

    Mailer boxes provide excellent protection for your products during transit. These boxes are made from durable materials and can withstand the rigors of shipping.


    You can easily customize the boxes to fit your specific products. Yes, mailer boxes come in various sizes and are perfect for branding, logos, or other designs you want to print.


    These boxes are stackable and very suitable for warehouse storage. With this layout, mailer boxes can help optimize space and improve organization.


    Today, you can find mailer boxes made from recycled materials that are recyclable. Eventually, using eco-friendly packaging options can reduce your environmental impact.

    Mailer Boxes Are Lightweight

    Yes, mailer boxes are lightweight and will help you reduce shipping costs.

    What to Consider When Getting a Mailer Box to Ship Your Products?

    If you are interested in getting a mailer box for shipping your products, there are some factors you should consider.

    Here they are!

    The Right Size

    Remember to choose the right box size according to the products you need to ship. Your mailer box should be large enough to accommodate your products. Also, your box should leave enough space. This way, you can prevent any movement during transit and reduce the risk of damage to your products.


    If you want to create a unique unboxing experience or reinforce your brand identity, look for mailer boxes that can be customized.


    Always look for a high-quality mailer box made from sturdy and durable materials, such as paperboard. Remember that the material should withstand the inflexibilities of shipping and protect your products.

    Closure Method

    Consider the closure method you need for your mailer box. Some options include self-sealing adhesive strips, tuck flaps, or interlocking tabs. Remember, you should also choose a closure method that is secure and easy to use.


    Compare prices from different suppliers. This way, you can get the best value for your money. However, you should also keep in mind that cheaper options may not always provide the same level of quality or protection.

    Environmental Impact

    If sustainability is important to you, look for mailer boxes made from eco-friendly materials. Some suppliers like Silver Edge Packaging offer environmentally friendly mailer boxes.


    Consider the number of mailer boxes you need. Then, choose a supplier that offers bulk discounts for larger orders to help you reduce costs.

    Considering all the factors above, you can choose the right mailer box for your shipping needs.

    Summing Up

    Undoubtedly, a mailer box is the ideal box you need to ship your products safely. However, you should also get the perfect box size according to your product’s needs and specifications. By shipping your products in mailer boxes, you can rest assured that they will arrive securely in customers’ hands.

    Happy shipping!


    How to measure boxes for shipping?

    To measure the right boxes for shipping, you need to consider the product’s dimensions.

    How to measure the dimensions of a box for shipping?

    The dimensions of your box should be big enough for your product to fit and be secure inside the box. Most importantly, your product should be snug inside the box.

    What size mailer do I need?

    To get the right size for your mailer box, you should focus on:

    • Product dimensions
    • Type of product
    • Shipping method
    • Void fill
    • Your brand image

    How to measure a poly mailer?

    If you want to use a poly mailer, you can measure a poly mailer with these steps:

    • Measure the length, width, and height of the product you want to ship
    • Add 1/4 inch to the product height twice
    • Add the product length to get the minimum poly mailer length
    • Now, add 1/4 inch to the product height
    • Then, add the product width to get the minimum poly mailer width


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