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Envelope Mailers
Durable, Branded, and Built for Simplicity
What Are Envelope Mailers?
Rigid Paperboard Mailers for Documents and Flat Products
Envelope mailers are flat, self-sealing packages designed to ship documents, inserts, promo materials or lightweight products. Think of them as the premium, branded version of a FedEx-style overnight mailer but made from recyclable, high-caliper paperboard with full-color printing.
When Simplicity and Strength Are Key
Not as common as folding cartons or shipping boxes, envelope mailers are a practical solution for brands that need slim, protective packaging for items that can’t bend or crease in transit.
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Custom product boxes made in the U.S.
We don't charge for rushes - we accomodate you where we can.
Have questions? Talk to a real human.
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Chat with us - Use the chat bubble at the bottom right
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Call us (800) 555-1778
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Email us - quotes@boxcoop.com
Compare costs across different styles to find the box that fits your product.
How Did We Come Up With This Cost?
Ever wonder how we calculate your carton costs? Our Custom Product Box Costs Explained guide uses quick visuals and simple examples to show exactly what goes into your quote—and how to make the most of your retail packaging budget.
Features of Our Envelope Mailers
Made from Heavy-Duty Paperboard
We use thick, rigid paperboard (24pt or 28pt) to create mailers that can protect your contents during shipping without requiring additional void fill or corrugated boxes.
Peel-and-Seal Closure
Each mailer has a double-sided adhesive strip for quick, secure closure. Some options have a second strip for easy customer returns.
Custom Sizes and Layouts
Whether you’re mailing flat prints, promo kits or lightweight products like sticker packs, pins or documents, we can size the envelope to your exact specs.
Professional Branding
Unlike stock mailers, these can be fully printed with your branding, logo, campaign graphics or messaging. You can also choose from matte, gloss or soft-touch coatings.
Ideal Use Cases for Envelope Mailers
Marketing Collateral: Flat brochures, catalogs, samples, press kits
E-Commerce Inserts: Subscription inserts, postcards, loyalty gifts
Event Materials: Trade show kits, product launch invites, branded documents
Retail Merchandise: Flat accessories, pins, stickers or small apparel
Benefits of Paperboard Envelope Mailers
Lightweight and Low-Profile
Envelope mailers minimize shipping weight and reduce dimensional pricing, saving you money on direct-mail campaigns or sample shipments.
Sturdy Without the Bulk
Our rigid mailers offer more protection than a poly mailer or paper envelope, without the bulk of a box. Perfect for flat or thin contents that need to arrive crisp and undamaged.
Eco-Friendly and Recyclable Made from recyclable paperboard and printed with soy-based inks, our envelope mailers support your brand’s sustainability goals.
Fully Customizable
Edge-to-edge artwork to interior printing, foil stamping or embossed logos, we can make your mailers look as sharp as they function.
Envelope Mailer FAQs
What Are Envelope Mailers Made Of?
Our envelope mailers are made from high-caliper coated paperboard, 20pt-28pt depending on the required rigidity.
Can These Mailers Be Printed Inside and Out?
Yes! We offer full coverage print inside and outside for a branded experience from opening to finish.
Are Envelope Mailers Recyclable?
Yes. All paperboard mailers we produce are 100% recyclable and made from sustainably sourced materials.
What Are the Minimums for Custom Envelope Mailers?
Typical minimums start at 500 units but we may accommodate smaller runs depending on the size and finish.
Good for Fragile Items?
Best for flat, semi-rigid items. For fragile or dimensional products we recommend pairing with inserts or our folding carton or litho-lam options.
Get Started on Your Custom Envelope Mailer Project
Tell us what you need to ship or promote and we’ll help you design a rigid paperboard envelope mailer to fit your brand and protect your content.
Work with Experts in Premium Paperboard Packaging
At The Box Co-op we focus exclusively on paperboard packaging from custom boxes to branded mailers. If you need a clean, professional way to deliver flat products our envelope mailers are built to impress.