Fragile Goods Mailer Boxes Sized Around What Breaks
A fragile goods mailer box is a roll-over lid mailer cut closely around glass, ceramics or anything that chips, usually in thicker B-flute board. Paired with a die-cut board insert, it stops the item moving, which is what breaks most things in the post.
From £0.25 a box exact price on a written quote, within one working day
- Free design proof before anything is printed
- Production takes 4 to 6 working days after proof approval
- Free tracked UK mainland delivery in 2 to 3 working days
- Misprints or damage reported within 10 days with photos are reprinted or refunded
- Low minimums, quoted per job
Specification
What fragile goods mailer boxes from us are made of and how they are measured. Anything not listed here, ask in the quote.
| Style | Roll-over lid mailer with locking side ears, sized tight to the insert |
|---|---|
| Board | Brown kraft or white-lined; B-flute 3 mm usual, E-flute 1.5 mm for small items |
| Size range | 100 x 80 x 30 mm to 600 x 450 x 450 mm, inside |
| Typical start | 220 x 160 x 100 mm inside, set by the item and insert |
| Plain, one colour, two colours or full colour; outside, inside or both | |
| Inserts | Die-cut board inserts, dividers and paper void fill, quoted with the box |
| Finish | Matt or gloss varnish, white underprint on kraft |
| Supplied | Boxes and inserts flat, creased and bundled |
| Price | From £0.25 a box; exact price depends on size, board, print and quantity |
How to measure for a fragile goods mailer box
Measure the item at its widest points, including handles, spouts or lids. If it will sit in an insert, the insert sets the inside size, so tell us the item size and we size both together.
Without an insert, add room for wrapping and fill on every side as well as the usual 3 to 5 mm of clearance. Send the item size and how you plan to wrap it.
Which board for which job
B-flute at 3 mm is our usual board for breakables, as its deeper flute gives thicker walls and more give at the corners. E-flute at 1.5 mm is fine for a small, well-held item such as a single glass jar in a tight insert.
Design Your Fragile Goods Mailer Mailer Box
Drop your logo on a real photo of our fragile goods mailer boxes, set the size and quantity, and send it. A designer sets up the real dieline and sends a free proof.
Your logo is placed on a real photo of our box. A designer redraws it to scale on the dieline and sends a free proof before anything is printed.
What is a fragile goods mailer box?
It is a one-piece corrugated mailer with a roll-over lid, chosen in board and size for items that crack, chip or shatter. The box is cut close to the item, or close to an insert that holds the item, so nothing can slide inside.
The lid tucks in at the front and the side ears lock it shut, which leaves no weak taped seam along the top. It belongs to our ecommerce and subscription mailer range with insert fitted and subscription styles.
Why do fragile items break in the post?
Most breakages come from movement, not from the box being crushed. An item that can travel even a few millimetres knocks against the wall every time the parcel is dropped, turned or stacked.
The other cause is a point blow on a corner or an edge where the item touches the box wall. So the job is to hold the item still and keep it away from the walls. A close-fitting box with an insert does both.
Who sends breakables in mailer boxes?
Small makers and shops whose products would never survive a soft bag. These are the jobs we see most often.
- Glassware sellers posting tumblers, wine glasses or a carafe.
- Potters sending mugs, bowls and small vases.
- Candle makers posting candles in glass jars or ceramic pots.
- Fragrance and skincare brands sending glass bottles and droppers.
- Artists posting small framed prints with a glass front.
- Gift shops sending china ornaments and small figurines.
How do you pack a glass item in a mailer box?
The method below works for a single glass item or a pair. Practise it once with a cheap item before you post the first real order.
- Fold the box and drop the die-cut board insert into the base.
- Wrap the item in a sheet of tissue or paper so it does not rub on the board.
- Seat the item in its cut-out so it sits level and cannot rock.
- Fill any gap above the item with paper void fill until the lid just touches it.
- Close the lid, lock the side ears and add a sticker or tape strip over the front.
Give the closed box a gentle shake next to your ear. If you hear anything move, add fill and try again.
Which board protects fragile goods better?
B-flute is 3 mm thick with a deep flute. It has more give when a corner is knocked and gives thicker walls between the item and the outside world, so it is our usual starting point for glass and ceramics.
E-flute is 1.5 mm and prints more sharply. It suits a small item such as a single jar held tight in an insert, where the insert does most of the work. Both come in brown kraft or white-lined board. The guide to E-flute versus B-flute board explains the difference in more detail.
What size fragile goods mailer box do I need?
With an insert, the insert sets the size, and we work both out from the item. Without one, allow for wrapping and fill on every side. Our usual starting point is 220 x 160 x 100 mm inside.
| Item | Inside size to try | Insert or fill |
|---|---|---|
| Single candle in a glass jar | 120 x 120 x 110 mm | One-aperture board insert |
| One ceramic mug | 160 x 130 x 120 mm | Board insert with handle slot |
| Two tumblers | 220 x 160 x 100 mm | Two-aperture board insert |
| Set of three glass bottles | 250 x 120 x 160 mm | Three-aperture insert |
| Small framed print | 260 x 210 x 50 mm | Corner pieces and paper fill |
| Small vase | 200 x 200 x 220 mm | Board insert and void fill |
Most of these fit the Small Parcel band of 450 x 350 x 160 mm, though a tall vase can tip into Medium Parcel. Check the current band limits before you order. Our guide on how to measure a mailer box shows where to put the ruler.
Board inserts or paper void fill?
A die-cut board insert holds an item in a fixed spot. It suits products of one shape sent again and again, such as a range of candles or a set of bottles, and it makes packing quick and the same every time.
Paper void fill is flexible. It suits mixed orders and odd shapes, and it tops up the space above an insert. Many fragile orders use both. Our guide to mailer box inserts for fragile goods compares layouts.
Printing a fragile goods mailer box
A handling line on the outside, such as a "this way up" arrow or a fragile warning, tells sorters what is inside. It can sit in one colour on plain kraft or be part of a full colour design.
Inside the lid, a short unpacking note helps the customer lift the item out without knocking it on the insert. Leave a plain panel on the lid for the address label, so it never sits over the warning. Matt or gloss varnish keeps full colour print from scuffing.
Mistakes to avoid when posting breakables
- Choosing a box with room to spare and hoping fill will hold the item.
- Measuring a mug without its handle, so the insert cut-out is too small.
- Letting a glass item touch a wall or the lid directly.
- Packing two glass items in one cut-out where they can knock together.
- Picking E-flute for a heavy ceramic piece to save a few millimetres.
- Putting the address label across the fragile warning.
What if a box arrives damaged or misprinted?
Our promise covers the boxes and inserts we send. Report any misprint or damage within 10 days with photos and we reprint or refund. Open one bundle when it arrives and check a few boxes against the approved proof.
The full terms are on our returns and reprints page. It is worth reading before your first fragile order, so you know what to photograph.
How do I order fragile goods mailer boxes?
Send the item size, how many items go in each box, the board and the print you want. We quote the box and insert together in writing within one working day, from £0.25 a box, and make a free proof before anything is printed.
Production takes 4 to 6 working days after proof approval, and free tracked UK mainland delivery takes 2 to 3 working days. Ask for a quote for a fragile goods box or send a photo of the item on WhatsApp to +44 7578 382054.
Related mailer boxes
Other closures and finishes that start from the same idea.
Insert Fitted Mailer BoxesDie-cut board insert holds each item in placeFrom £0.25 a box
Ear Lock Mailer BoxesTape-free close for unboxing on cameraFrom £0.25 a box
Subscription Box MailersSame size every month, fresh print every quarterFrom £0.25 a box
Brown Kraft Mailer BoxesPlain kraft, one or two colour print if you want itFrom £0.25 a boxFragile Goods Mailer Boxes questions
Which board do you suggest for a fragile goods mailer box?
B-flute at 3 mm for most glass and ceramics, as it gives thicker walls. E-flute suits a small item held firmly in a tight insert.
Does a fragile goods mailer box come with an insert?
Not automatically. A die-cut board insert is quoted with the box, and we size the two together from your item measurements.
Can a fragile goods mailer box hold a mug with a handle?
Yes. The board insert can include a slot for the handle so the mug sits upright and cannot turn.
How tight should a fragile goods mailer box be around the item?
Tight enough that nothing moves when you shake it. With an insert, the cut-out holds the item; without one, wrapping and fill should touch all sides.
Can I print a fragile warning on the mailer box?
Yes. A warning or a this-way-up arrow can go on the outside in one colour or as part of a full colour design.
Will two glasses travel safely in one fragile goods mailer box?
They travel best with a two-aperture board insert, so each glass has its own cut-out and they cannot knock together.
Can a fragile goods mailer box take a framed print?
Yes, for small frames. Board corner pieces and paper fill keep the glass away from the walls of the box.
Does a fragile goods mailer box need tape?
The lid locks with its side ears, but a sticker or tape strip over the front adds a seal for breakables in transit.
Can the insert in a fragile goods mailer box be printed?
Yes. Inserts can be printed in one colour or full colour, often with the product name beside each cut-out.
Can a fragile goods mailer box hold perfume bottles?
Yes. A board insert with one cut-out per bottle keeps each upright and apart. Measure caps and collars as well as the bottle body.
How big should a fragile goods mailer box be for a vase?
Measure the widest and tallest points, then let us size the insert and the box together. Tall vases can move into the Medium Parcel band.
Is there a separate page about inserts for fragile goods mailer boxes?
Yes. If the insert matters most to your order, see our insert fitted mailer boxes for more layouts.
Your question is not here? Ask on WhatsApp or call +44 7578 382054.
Tell us what you post
Send the product, a rough inside size and a quantity. We reply in writing within one working day with a price and a free design proof. Prefer to talk? Call +44 7578 382054 or message us on WhatsApp.