Mailer Box & Courier Carton Manufacturer in Rajkot, Gujarat

A mailer box is a one-piece die-cut corrugated box with a lid hinged on the back wall and tabs that lock into the front, so it ships flat, folds up on the packing bench and closes without tape. We manufacture the corrugated mailer box, the roll-end mailer and the plain courier carton in 3-ply E or B flute at Shapar-Veraval GIDC, Rajkot, to any internal dimension, plain or printed.

These are the shipping boxes for e-commerce orders that travel alone through a courier network: the box is the shipper, the protective layer and, on opening, the brand. Because it is made to size rather than taken from a stock list, the pack is as small as the product and its cushioning allow, which is what keeps courier volumetric weight down.

In Gujarat the buyers are D2C brands in Surat and Ahmedabad shipping garments, textiles and cosmetics, subscription-box packers, Rajkot and Jamnagar spare-part sellers sending bearings and fittings by courier, and marketplace sellers in Vadodara. For the broader pack, see packaging for e-commerce and D2C brands.

Mailer box size is any internal dimension; the three styles and two flutes cover the usual e-commerce range. The table gives each format and what it is best for.

Liners are 120 to 180 GSM kraft or semi-kraft, and each specification is tested for bursting strength, edge crush and box compression to IS 2771 as for our 3 ply corrugated boxes. The style is explained in the die-cut carton glossary entry and the flutes in the flute types entry.

Size. Internal dimension on each axis is the product dimension plus twice the cushion thickness plus 3 to 5 mm clearance; the external dimension adds twice the board caliper, about 3 mm for 3-ply B flute. Measure the product, not the old box.

Volumetric weight. Indian express couriers bill the higher of actual weight and length × width × height in centimetres divided by 5000; some surface services use 4000 to 4500. A 40 × 30 × 30 cm carton is billed at 7.2 kg whatever it weighs; the same product in a 34 × 26 × 24 cm box is billed at 4.24 kg, and carriers round up to the next 0.5 kg slab. Run your sizes through the volumetric weight calculator and read how to reduce dimensional weight.

Flute and style. E flute for compact, printed packs; B flute where the contents are heavier or the pack is stacked. Tuck-top for most orders, roll-end where the side walls should double as cushioning, courier carton where board cost matters more than unboxing. Replace loose fill with a die-cut EPE fitment or an air bubble bag and the box usually drops a size. The full sequence is in right-sizing your packaging.

Every custom mailer box starts from a dieline drawn to your internal dimensions and style. Board is specified to E or B flute with the liner GSM on the quote, then printed flexo in up to 3 colours from plates made to your artwork; offset-laminated board is used on request where photographic print is needed. The difference is explained in flexo vs offset printing on corrugated boxes.

The printed board is die-cut and creased in one stroke with a steel-rule die made to the dieline. The locking tabs, hinge creases, thumb notch and any tamper strip or hand hole come from the die, which is why a mailer box needs no tape and no separate fitment. Blanks are stripped, stacked and strapped flat.

A first-article sample is erected and fitted to the product before the run, and samples from the run are tested for bursting strength, edge crush and box compression to IS 2771. For sealing a courier carton or adding a branded strip over the lid, we supply printed BOPP tape or kraft paper tape with the boxes.

• Garments and textiles, Surat: E flute tuck-top printed mailer boxes for sarees, dress material and apparel shipped by courier. See packaging manufacturer in Surat.
• Cosmetics and D2C brands, Ahmedabad: printed mailers with a die-cut insert for bottles and jars.
• Spare parts by courier, Rajkot and Jamnagar: B flute courier cartons with an EPE fitment for bearings, pump spares and brass fittings. See brass parts and hardware packaging.
• Subscription boxes, Ahmedabad and Vadodara: one mailer box size per plan, printed inside and out, shipped flat to the packing partner.
• Electronics and accessories, Ahmedabad: roll-end mailers whose double walls cushion chargers, speakers and instruments.
• Food and FMCG samplers, Anand and Vadodara: courier cartons sized to the sampler count so the pack is billed on actual weight.

There is no fixed price list. Mailer box price is quoted per piece within one working day against your internal dimensions, print and quantity. Six things move the number.

1. Blank area. A die-cut mailer uses more board than a slotted carton of the same internal size, so trimming the box to the product saves board and freight together.
2. Flute and liner GSM. B flute uses more medium than E; 180 GSM liners use more fibre than 120 GSM.
3. Printing. Each flexo colour adds a plate and a pass; offset lamination adds a printed sheet and a lamination step.
4. Die. One steel-rule die per size and style, a one-time cost spread over the run and reused on repeats.
5. Features. Tamper strips, inside print, hand holes and inserts add die complexity or parts.
6. Quantity and freight. Plates and die are fixed, so unit price falls with volume; freight is quoted to your door by lane.

Ask for tooling shown separately from the per-piece price. Send the product dimensions, weight, artwork and monthly volume and we return a per-piece quote with the volumetric weight of the pack worked out.

MOQ is set per size and design, because the die and plates must be spread over the run; a plain courier carton runs at lower quantities than a printed roll-end mailer. The quote states the quantity at which each option makes sense. Lead time is stated on the same quote and runs from artwork proof and sample approval.

Dispatch lanes from Shapar-Veraval: Rajkot and Saurashtra same day or next morning; Morbi, Jamnagar and Gondal 1 day; Ahmedabad, Surat and Vadodara 1 to 2 days; Maharashtra, MP and Rajasthan 2 to 3 days; South and East India 4 to 6 days. Boxes ship flat and strapped; recurring supply is scheduled against your order volume.

Corrugated is ISPM-15 exempt, so export parcels need no fumigation certificate, and container stuffing at Mundra or Kandla is coordinated with your CHA.

The mailer box HSN code is 4819 10 10, cartons, boxes and cases of corrugated paper or paperboard, the same heading as any corrugated box. Other corrugated cartons fall under 4819 10 90. Confirm the 8-digit item with your CA or CHA before the first invoice; we invoice under GST 24CUBPJ4107N1ZP and match the code on your purchase order. The full list is in our post on HSN codes for packaging materials.

From Shapar-Veraval GIDC we deliver same day or next morning to Metoda GIDC, Lodhika GIDC, Aji GIDC, Navagam, Gondal Road, Kuvadva Road, Bhakti Nagar, Kalawad Road and Mavdi, and to Gondal, Jetpur and Wankaner. See packaging manufacturer in Rajkot.

Among e-commerce boxes manufacturers in Gujarat we serve Surat textile and apparel sellers on a 1 to 2 day lane as a courier box supplier in Surat, Ahmedabad D2C and cosmetics brands in 1 to 2 days, Vadodara and Anand in 1 to 2 days, and Morbi, Jamnagar, Gondal, Bhavnagar and Gandhidham. See packaging manufacturer in Gujarat, packaging manufacturer in Ahmedabad and the state page for corrugated box manufacturers in Gujarat.

Beyond the state we ship to Mumbai, Pune, Delhi NCR and Bengaluru fulfilment centres, and hand export consignments to your CHA at Mundra or Kandla. Call +91 85113 39338 or send the product dimensions and artwork for a quote within one working day.