The Box Files · File 05
File 05What custom
mailers cost
Most packaging sites make you request a quote before showing a single number. Here are the honest industry ranges — and what moves them.
The realistic ranges
For a standard-size custom printed mailer box (around 10 × 8 × 4 inches, E-flute, full-color outside), typical industry pricing lands in these bands:
| Quantity | Typical per-unit range |
|---|---|
| 500 | $1.50 – $3.50 |
| 1,000 | $1.10 – $2.50 |
| 2,500 | $0.85 – $1.80 |
| 5,000 | $0.65 – $1.40 |
These are honest ballparks, not our price list — your quote depends on the specifics below, and exchange rates, freight, and board prices shift over time. But if a quote lands far outside these bands in either direction, ask why.
The five things that move the number
- Quantity. The biggest lever by far. Setup costs (printing plates, cutting dies) are spread across the run — which is why unit prices fall so steeply from 500 to 5,000, and why minimums exist at all.
- Size. Price tracks board area. A box twice as large uses roughly twice the material.
- Print coverage. Plain kraft with a one-color logo sits at the bottom of each range. Full-color printing inside and outside sits at the top — inside printing effectively doubles the print job.
- Board grade. Standard E-flute is the baseline; heavier flutes and higher ECT ratings add cost.
- Finishes. Matte or gloss lamination, foil, embossing — each adds a per-unit premium and sometimes setup fees. Most brands under 5,000 units don't need any of them.
If the budget is tight, cut print coverage before you cut quantity. A one-color kraft box at 1,000 units usually beats a full-color box at 500 — on unit price and on cost per customer reached.
Watch the quote's fine print
When comparing quotes, check whether plates, dies, and freight are included or billed separately — a low unit price with $300 of unlisted setup fees isn't a low price. Our quotes include them in the single number, which is the way we think it should be done everywhere.
Put it to work
Tell us what you're packing — product, rough dimensions, quantity — and we'll send back a straight quote, including a cheaper alternative if one exists. Minimum order: 500 units.
Request a quote