Custom Flexible Kraft Mailers
Custom flexible kraft mailers from 100 — brown or white paper mailers with a peel-and-seal flap and an optional tear strip, flat or gusseted, printed with your mark for apparel, prints and flat goods.
Paper that bends around the order instead of a box around it
- Paper
- Kraft paper, brown or white, single or double ply; long-fiber kraft for tear resistance
- Styles
- Flat, gusseted, tear strip with return seal, rigid back panel
- Closure
- Peel-and-seal adhesive flap; second strip for returns
Order online
Order flexible kraft mailers
Starting from $1.10 per unit
Printed to your artwork or plain, sold in runs of 100 up to 5,000 units per product online. Freight to the US, UK, Canada and Australia is inside the price.
How an online order runs
- Add the units you needThen check out with your delivery address. Add other products to the same order on the way.
- A digital proof comes backLaid on the dieline, before anything prints. Change it as often as you need.
- Pay once you approve itPay by PayPal invoice or bank transfer after you approve your digital proof, or cash on delivery in the US and Canada.
- We make it and ship it deliveredYour delivery date is confirmed with the proof, against the spec and your fill date. Freight and customs are handled on the way to you.
Another size, board or finish, or more than 5,000 units? Send the spec for a price instead. Freight by market and our terms cover delivery and remakes.
Get a price for Flexible Kraft Mailers
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- Free dielineThe flat drawing comes with the quote, before you commit.
- Proof before pressNothing is printed until you have seen it laid on the dieline.
- Die kept for reordersTooling is paid once. Every reorder skips straight to press.
- Quoted in four marketsUS, UK, Canada and Australia, in the delivery currency.
Flat or gusseted
| Flat mailer | Two paper faces, for thin goods: prints, documents, folded apparel |
|---|---|
| Gusseted mailer | Expanding sides and base for thicker items like sweaters and books |
| Mailer with tear strip | Opens cleanly along a pull strip; second strip for returns |
| Rigid-back mailer | Paperboard back panel for photographs and prints that must not bend |
How strong the paper needs to be
Kraft paper strength is set by weight and by how many plies the mailer has. A single heavy kraft ply suits apparel; two plies or a reinforced seam suit books and heavier items with corners that press into the paper. Long-fiber kraft resists tearing far better than recycled white paper of the same weight, which matters when a parcel is dragged across a sorting belt.
Padded or unpadded
An unpadded mailer protects from dirt and scuffs only. If the goods need cushioning, a paper-padded version adds a layer of shredded or honeycomb paper between the plies without introducing plastic. That version is covered on our page for paper padded mailers with no plastic.
Print on a paper mailer
- One- and two-color flexographic print reads well on brown kraft.
- White kraft takes full-color artwork with brighter results.
- A return address block and a space for the shipping label are planned in.
- Inside print is possible on gusseted styles for a message on opening.
Send the largest item you ship in it and how thick it is folded. That sets the size and whether you need a gusset.
When a mailer box is the better choice
Fragile items, anything with sharp corners, and gifts meant to be unboxed are better in a corrugated mailer. A paper mailer is for goods that can flex. The boxed alternatives are on our page for mailer boxes built for shipping.
Flexible Kraft Mailers — specification
The rows that are specific to this build first, then what applies to every job we run. Anything not listed is a question, not a limit — send the brief.
This build
- Paper
- Kraft paper, brown or white, single or double ply; long-fiber kraft for tear resistance
- Styles
- Flat, gusseted, tear strip with return seal, rigid back panel
- Closure
- Peel-and-seal adhesive flap; second strip for returns
- One to two colors on brown kraft, full color on white kraft
- Recycling
- All-paper construction, recyclable with paper
- Minimum
- 100 mailers per size
On every job
- Print process
- Flexo in one to four colors straight onto the liner; litho-lamination where the box needs full color or a photograph.
- Color
- Flat colors on kraft. Full color needs a white top liner or a laminated sheet, because brown shifts every color warm.
- Tolerance
- Cutting plus or minus 1.5 mm. The flute compresses, so corrugated runs wider than folding board.
- Tooling
- No die on a regular slotted box, which is cut on a slotter. Die-cut mailers and trays need one, made once and kept.
- Food contact
- Food-grade liners and a vented build where the box carries hot food.
- Sustainability
- High recycled content through liners and flute as standard, and the box recycles whole if it is sealed with paper tape.
- Artwork
- Vector PDF or AI, 3 mm bleed, 4 mm safe area, fonts outlined. We check every file and send a proof before press.
- Dieline
- Supplied free with the quote, before you commit. Yours whether or not you order.
- Sample
- A plain unprinted sample at the finished size on request, for fit and construction.
- Reorders
- Skip the tooling and go straight to press at a lower unit price.
- Lead time
- Quoted with the price against your fill date rather than promised before we have seen the spec.
- Markets
- United States, United Kingdom, Canada, Australia — priced in the delivery currency, freight included.
Boards and films we build flexible kraft mailers on
Corrugated is a fluted sheet glued between two liners, and the flute decides nearly everything: how it prints, how it dents, how high it stacks. These are the grades we run.
E flute
About 1.5 mm. Prints well and folds crisply; dents under a stack. Retail boxes, mailers and light shippers.
1.5 mm, single wallB flute
About 3 mm. The working default for parcels — takes print reasonably and stacks reasonably. Most shipping boxes are B.
3 mm, single wallC flute
About 4 mm. More cushioning than B, slightly less stacking strength per weight. Common on grocery and produce cases.
4 mm, single wallBC double wall
B and C glued together, about 7 mm. Heavy or fragile goods, pallet stacking, anything over roughly 15 kg.
7 mm, double wallKraft liner
Brown, strong, absorbent. One or two flat colors flexo print well on it; photographs drink into the brown and go muddy.
Outer and inner linerWhite top liner
A bleached outer liner for full-color print on corrugated. Costs more and marks more easily than kraft.
Outer liner onlyRecycled-content corrugated
High post-consumer fiber through liners and flute. The default for shippers; a slightly grayer brown and no loss of strength at grade.
All flutesCoated and water-resistant
A coating or a wax-free barrier liner for damp stores and cold chains. Check the recycling stream before printing a claim on it.
B and C fluteNot sure which? Say what goes in it and where it is sold — the material follows from that. Our notes on recycled, recyclable and compostable cover which claims each stock can honestly carry.
- 01
Send what you have
A dimension, a photograph beside a ruler, or the product itself. No technical drawing needed — that part is ours.
- 02
We quote and draw
A price, a dieline and a date come back together. If a different build would suit the product better, that is in the reply too.
- 03
Approve the dieline
The flat drawing is yours to check: which panel is the front, where the folds fall, how deep the cavity really is.
- 04
Artwork on the dieline
You place your design on the flat we sent, or we place it for you, and you see a proof before anything goes to press.
- 05
A sample if you want one
A plain unprinted sample at the finished size shows fit and construction — the things a drawing cannot.
- 06
Cut, printed, shipped
The die is cut once and kept, so every reorder skips the tooling and goes straight to press at a lower unit price.
Format
Vector PDF or AI where possible. Raster artwork at 300dpi at final size, in CMYK.
Bleed
3 mm past every trim line, so a fraction of drift on the cutter never leaves a white edge.
Safe area
Keep type and anything important 4 mm inside the cut and away from every fold.
Color
Convert to CMYK before sending. Uncoated stock prints lighter; a spot color is the only exact match.
Fonts
Outline them or supply the files. A missing font substitutes silently and the proof will not match.
Barcodes
On a light, matte, unvarnished patch with the quiet zone clear — a code on gloss fails the scanner.
Not set up that way? Send it anyway — fixing a file is a short conversation, and we check every one before press. Our guide to preparing print files covers each point.
Corrugated takes fewer finishes than folding board, and the ones it takes it takes well.
Flexo on kraft
One or two flat colors straight onto brown. Cheap, fast, honest.
Litho-lamination
An offset sheet glued to the flute: full color and photographs on a shipper.
Aqueous varnish
Scuff resistance with no film, so the box still recycles whole.
White top print
Full color flexo on a bleached liner; brighter, and it marks more easily.
Inside print
A second pass on the inner liner — the panel a customer sees first.
Printed tape seal
The brand applied at the last moment, on paper tape that recycles with the box.
Not sure which suits the shelf it sells from? Say where the product is sold and we suggest one — our notes on specialty finishes show them on real boxes.
Sizing a corrugated box against the carrier, not the catalog: flexible kraft mailers
Corrugated is cut to your internal size, so the box goes round the product rather than the product going into a stock size. That is where the money is: a box 20 mm smaller each way is often a whole postage band cheaper.
- Internal dimensions
- Length, width and depth of the space you need. Board thickness is added outside that, and the flute is thicker than people expect.
- Clearance and void fill
- 5–10 mm a side for a rigid product. Size it properly and you need no void fill at all, which is cheaper and better received.
- Stacking
- Tell us how high the boxes stack on a pallet or a shelf. Edge crush grade is specified from that, not guessed.
- Weight
- The contents weight sets the flute and the liner grade. Over about 15 kg we move to double wall.
- Score allowance
- Corrugated needs more room at the folds than boxboard. The dieline accounts for it; a box drawn from flat dimensions comes out tight.
- Cutting tolerance
- Plus or minus 1.5 mm on corrugated, wider than folding board because the flute compresses.
Not sure your numbers are right? Send the product dimensions rather than the box dimensions and we work the box out — the full method is in our guide to measuring for a box.
Interactive · five steps · no sign-up
Build your Flexible Kraft Mailers in 3D
Pick a shape, type a size, choose a board and a finish. The preview on the left redraws as you go, and the spec lands with us exactly as you set it.
Frequently asked questions
Got a question about flexible kraft mailers? The answers below cover what we get asked most. If yours is not here, send it with a brief, message us on WhatsApp, or call +1 503-461-4788 — we reply the same working day.
What can I ship in flexible kraft mailers?
Goods that can flex: folded apparel, books, prints, documents and soft accessories.
Are flexible kraft mailers waterproof?
No. They resist light splashes but are not waterproof. For wet conditions a poly mailer is safer.
Are flexible kraft mailers padded?
The standard versions are not padded. A paper-padded version adds paper cushioning between the plies.
Can flexible kraft mailers have a gusset?
Yes. Gusseted mailers expand at the sides and base for thicker items like sweaters and books.
Do flexible kraft mailers have a return strip?
They can. A tear strip opens the mailer cleanly and a second adhesive strip seals it again for a return.
Are flexible kraft mailers recyclable?
Yes. They are made entirely of paper and go in the paper recycling.
Can flexible kraft mailers be printed in full color?
Yes, on white kraft. Brown kraft is usually printed in one or two strong colors.
Will a flexible kraft mailer tear in transit?
Long-fiber kraft resists tearing well. For heavier items we use two plies or a reinforced seam.
Can I ship photographs in flexible kraft mailers?
Yes, in the rigid-back style with a paperboard panel so the prints cannot bend.
Are flexible kraft mailers cheaper to ship than boxes?
Usually. They are lighter and thinner than a box, which often puts them in a lower postage or dimensional weight band.
What size flexible kraft mailer do I need?
Measure the largest item as you fold it for shipping, including thickness. We size the mailer and gusset from that.
Same range
More mailer boxes we make
Assorted Mailer Boxes
100 boxes per size
Corrugated Literature Mailers
100 boxes
Ear Lock Mailer Boxes
100 boxes
Foldable Mailer Boxes
100 boxes
Mailer Boxes with Inserts
100 boxes with insert
Paper Padded Mailers
100 mailers
Self Seal Mailing Boxes
100 boxes