Snack Mailer Boxes

Packaging That’s Practical, Protective & Presentation-Ready

Perfect for subscription snacks, food startups, promotional kits, or retail samplers—our snack mailer boxes combine performance and eye appeal in every shipment.

Food-Safe Materials That Keep Snacks Secure

We build boxes that protect snacks from crushing, moisture, and handling damage.

• E-flute or B-flute corrugated cardboard – Strong yet lightweight
• Food-safe liners or coatings – Optional grease- or moisture-resistant inner layers
• Natural kraft or white premium stock – Ideal for eco-conscious brands
• Optional laminated surfaces – For added barrier protection and clean aesthetics

Custom Sizing & Layouts for All Snack Types

Whether it’s chips, trail mix, cookies, or health bars—we size your box to fit your lineup.

• Compact single-snack mailers or multi-compartment snack kits
• Tuck-top, roll-end front tuck (REFT), or snap-lock designs
• Custom inserts, trays, or dividers for separation and freshness
• Flat-packed or assembled delivery depending on your fulfillment needs

On-Brand Printing That Tells Your Flavor Story

Use every panel of your snack mailer to build appetite and brand loyalty.

• Full-color CMYK or Pantone printing
• Gloss, matte, or soft-touch lamination
• Foil stamping and spot UV for premium appeal
• QR codes for promos, nutrition info, or unboxing videos
• Inside printing for fun facts, messaging, or care instructions

Functional Features Built for Shipping & Unboxing

Your box performs beyond the mailbox.

• Durable flaps and secure locks for tamper resistance
• Lightweight and stackable for bulk shipments
• Optional peel-and-seal closure or tape-ready design
• Eco-friendly and recyclable for sustainable brand alignment

The 3Ps of Snack Mailer Box Packaging

• Presentation: Vibrant graphics and well-organized interior layouts create a satisfying unboxing moment.
• Preservation: Moisture barriers and food-safe coatings help maintain taste and texture.
• Protection: Rigid fluting and inserts shield snacks from crushing or shifting during delivery.

Why 5000+ Snack Brands & Subscription Services Choose Us

From health foods to gourmet indulgences—we build packaging that supports your growth and brand.

• No minimum quantity required
• Free 3D mockups and structural consultation
• Fast turnaround with U.S.-based printing and delivery
• FSC-certified, compostable, and recyclable options
• Total customization from dieline to delivery

Get a Free Quote Today

Ship your snacks in a box that’s as fresh and flavorful as the products inside. Call 0000 or email us now to launch your snack mailer box project with Custom Boxes Lab—where bold packaging fuels brand loyalty.

When measuring a custom box, there are a few technical specifications that must be considered to ensure proper design, manufacturing, and fit for the product. Here are the major technical things to measure a custom box:

Inside Dimensions (Critical for Product Fit)

• Length (L): The longest side of the box measured inside from one corner to the opposite corner.
• Width (W): The shorter side of the box measured inside perpendicular to the length.
• Depth/Height (D or H): Measured inside from the bottom to the top opening of the box. Always specify that dimensions are given in Length × Width × Height.

Outside Dimensions (Important for Shipping & Storage)

• Measure the outer surfaces of the box including material thickness.
• Outside measurements are used for pallet stacking, warehouse spacing, and shipping compliance.

Material Thickness (Board Caliper)

• The thickness of the packaging material (e.g., corrugated board, rigid stock, cardstock).
• Impacts both the internal usable space and external dimensions.

Flap Measurements

• For boxes with flaps (e.g., mailer or shipping boxes), measure:
• Inner flaps: Ensure they meet in the middle without overlapping too much.
• Outer flaps: Allow proper sealing without gaps.

Tolerances

• Account for manufacturing tolerances (usually ±1/16" or ±2mm depending on material).
• Ensure the product fits without being too tight or loose.

Volume Capacity

• Calculate internal cubic capacity (L × W × H).
• Helps in determining how much space the product will occupy and shipping efficiency.

Product Orientation

• Decide how the product sits inside the box and measure accordingly.
• Orientation affects whether length or width is the primary dimension.

Die-Cut Openings or Windows

• Measure exact placement, height, and width for any cutouts.
• Ensure structural integrity when adding windows.

Printing Bleed & Safe Zones

• Include measurements for:
• Bleed area: Extra space beyond the cut line for printing.
• Safe zone: Inner area where critical text or logos should be placed.

Closure Type & Locking Tabs

• Measure slots, tabs, or locks for boxes with custom closures.
• Precision is required to avoid misalignment during assembly.

Packaging Style

• Folds, creases, and scores must be measured for accurate dieline creation.
• Different styles (e.g., RSC, tuck-end, mailer, sleeve) require specific panel measurements.