Skip to content
FSC® material optionsNo minimum orderFree artwork review
+44 74 5340 5053[email protected]
Get a Quote
VIEWS
MAILER / KRAFT 01 / 04
Custom Double Wall Tray & Lid Packaging Boxes Roll-end structure Kraft board options Custom print surface
PRODUCT VIEW Reference presentation

Final structure, dimensions and board are developed around the actual product specification.

PRODUCT 01
CUSTOM SPECIFICATION
Custom Packaging / Mailer Boxes

Double Wall Tray & Lid Packaging Boxes

Double-wall trays are sturdy in nature since they contain the structure and design of a double wall. These boxes are designed to be used as a single tray or as a two-piece contracting carton that makes them look aesthetically pleasing. A double wall tray contains glued sidewalls that allow the consumers to conveniently structure the boxes.

01

Fit Built around product dimensions.

02

Board Selected around protection and presentation.

03

Print Artwork planned for the chosen surface.

04

Guidance Support from brief through production.

BUILD THE SPECIFICATION
Product Size Board Print
01 View specifications ↓ 02 Read buying guide ↓
Product details

Double Wall Tray & Lid Packaging Boxes

Custom Kraft Double Wall Tray & Lid Packaging Boxes

Choosing the right packaging for lightweight items is a difficult task. Product properties should be taken into account when manually selecting product packaging. There are so many packaging boxes available in the market that it becomes difficult to choose one. Ranking them according to your needs can help. If you want to pack and ship lighter weight products, must be packed in high-end-looking containers, need elegance, protection, and prominence of the product to be placed on tables in their containers than double wall tray.

Our trays are sturdy in nature since they contain the structure and design of a double wall box template. These boxes are designed to be used as a single tray or as a two-piece contracting carton that makes them look aesthetically pleasing. These double wall box template have high tensile strength and offer maximum impact resistance which makes them demandable for both industrial and packaging purposes.

Use our packaging boxes to safely ship any item. These large two-piece trays are designed to be used as one tray for storage, or as a two-piece box for easy transport. These boxes will protect your shipments from being crushed. When in the open position, these boxes act as a two-piece carton that will contract from the middle and provide extra strength. Our double wall box template are manufactured with materials that have higher strength and durability properties.

Thus, these trays are designed to be used in a variety of industries. Creating an impact on the market through low-cost and high-quality products, we represent a distinctive concept in both functionality and design. We offer these trays in different sizes, shapes, and colors. The cardboard material is sturdy and can also be customized according to your requests.

Tray And Lid Boxes

Tray and Lid boxes provide a simple, affordable way to package your product. Tray and lid boxes are strong enough to ship as is, but can also be used with a shrink sleeve, stretch film, or a combination of heat sealing and tabs for added security during shipment. These containers are perfect for holding small items and keeping them secure — no matter which way turns up. And when you need to find something fast, just flip open the lid to see what’s inside.

Contact us for more details: +44 20 3290 3203

Packaging specification

Double Wall Tray & Lid Packaging Boxes at a glance

Use these points as a starting specification. Final board, dimensions and construction should be confirmed around the product and its intended use.

Structure
Mailer / roll-end construction
Materials
Kraft and suitable corrugated boards
Dimensions
Developed around product size
Printing
Suitable custom print methods
Finishes
Selected functional or decorative finishes
Typical use
Ecommerce, retail, gifting and subscription
Kraft mailer packaging prepared for ecommerce use
APPLICATION Structure should follow the product and journey.
Designed around use

Where do Double Wall Tray & Lid Packaging Boxes work best?

Mailer boxes are useful where presentation and structural protection need to work together. The correct specification depends on what goes inside the box and what happens to it after packing.

WHERE THEY WORK
  • Ecommerce fulfilment
  • Subscription packaging
  • Retail products
  • Gift presentation
  • Clothing and accessories
  • Cosmetic and wellness products
SPECIFICATION CONSIDERATIONS
  • Product weight
  • Internal movement
  • Opening experience
  • Transport handling
  • Storage space
  • Assembly method
Structure & product fit

Build the packaging around the product

Packaging dimensions should start with the product and how it needs to be packed, protected, displayed, stored or transported. Internal space, board thickness, closures, inserts and assembly method can all affect the finished structural specification.

01

Measure the maximum product size Record the longest, widest and deepest points, including lids, closures, handles or projecting parts.

02

Define the required clearance Allow the space needed for packing, movement control, protective material or a fitted insert without unnecessarily increasing the box size.

03

Match structure to product weight Product weight, fragility and stacking requirements help determine suitable board strength and structural construction.

04

Consider how the packaging will be used Retail display, gifting, ecommerce, storage, fulfilment and transport can place different demands on the same packaging structure.

MEASUREMENT PRINCIPLE

Unless otherwise agreed, always confirm whether supplied measurements refer to the internal usable space or the external finished dimensions.

View measurement and dieline guidance
DIMENSION GUIDE Length × Width × Depth
L × W × D
Box dimension guide Three dimensional box diagram showing length, width and depth measurement directions. PRODUCT SPACE LENGTH (L) WIDTH (W) DEPTH (D)
L

Length Longest horizontal dimension.

W

Width Side-to-side dimension.

D

Depth Vertical or remaining dimension.

L × W × D Dimension order should be confirmed on the production specification or dieline before manufacture.
Packaging materials

Select material around the packaging requirement

There is no single board that suits every product. Material selection depends on structural strength, product weight, presentation, printing, storage, transport and any application- specific requirements.

Material family Typical role Surface & presentation Structural level
Kraft Paperboard Natural-looking cartons, sleeves, retail packaging and suitable lightweight structures. Brown or natural surface with distinctive print behaviour. Light–medium
Folding Boxboard Retail cartons, cosmetics, food, healthcare, gifting and other presentation-led applications. Smooth printable surface suited to detailed graphics. Light–medium
Corrugated Board Mailers, ecommerce, shipping, larger products and packaging requiring increased structural protection. Kraft or white liners with several printing routes available. Medium–high
Rigid / Greyboard Premium presentation boxes, luxury gifting and applications requiring a substantial non-folding construction. Usually wrapped with printed or decorative paper. High rigidity
MATERIAL DECISION
01 Product weight 02 Protection 03 Presentation 04 Print 05 Handling

Specification note: Board grade, thickness, flute, coating and any specialist requirements should be confirmed against the final product and intended use rather than selected from appearance alone.

Explore packaging materials →
Printing & finishing

Develop the print specification around the material

Printing and finishing options should be selected after the material and structure are understood. The suitable production route depends on the substrate, artwork, colour requirements, quantity, surface area and intended appearance.

01
PRINTING Choose the print process from the job specification
Digital Printing Suitable for compatible substrates and projects where digital production provides the appropriate quality and production route.
Lithographic / Offset Used where detailed graphics, controlled colour and suitable production volumes justify lithographic printing.
Flexographic Printing Commonly considered for suitable corrugated, kraft and transport-packaging applications.
Spot / Brand Colours Specific colours can be considered where brand consistency or restricted-colour artwork requires them.
02
FINISHING Add surface treatments only where they support the brief
Lamination & Coatings Matte, gloss or other suitable surface treatments can alter appearance, handling and surface protection.
Foil Metallic, coloured or decorative foil can highlight selected branding or graphic elements.
Embossing / Debossing Raised or recessed areas can introduce tactile depth where the board and structure support the process.
Spot UV & Specialist Effects Selective gloss, texture or other specialist treatments can be considered where technically suitable.
PRINT DECISION PATH Material first. Artwork second. Production method third.
01 Board
02 Artwork
03 Colour
04 Print
05 Finish
01

How does the mailer structure protect the product?

A mailer box uses folded board panels to create a self-contained structure with an integrated lid. Unlike a simple folding carton, the side walls and roll-end construction can provide additional rigidity around the packed item. The amount of protection, however, depends on the board grade, box dimensions and how closely the product fits inside.

Start by considering how the box will be handled. A lightweight retail item packed directly into a presentation mailer has different requirements from a heavier product moving through an ecommerce delivery network. Where movement inside the box could cause damage, an insert or closer internal fit may be more useful than simply increasing the overall box size.

02

Which kraft board should you specify?

Double Wall Tray & Lid Packaging Boxes can be produced from different board constructions depending on the product and required appearance. Lighter applications may suit a paperboard construction, while corrugated board is commonly considered where greater rigidity or transport protection is needed. The flute, liner and overall board specification should therefore be selected after the packed weight and dimensions are known.

Surface appearance also matters. Natural kraft has a visible brown tone and characteristic fibre appearance. That can work well where the packaging design is intentionally understated, but it also influences printing. A white or alternative printable liner may be preferable where the artwork depends on a different colour base or a particular print appearance.

03

How should the internal dimensions be calculated?

Measure the complete product at its widest, longest and deepest points. Do not base the carton only on a nominal product size if closures, accessories or other components extend beyond it. Any insert, protective wrap or internal component must also be included when calculating the usable space.

Excessive clearance can allow the product to move and may unnecessarily increase material use and shipping volume. Too little clearance can make packing difficult or place pressure on the product. The aim is a practical fit that allows efficient packing while providing the space genuinely needed for protection.

04

What should be considered before printing kraft mailers?

Artwork should be prepared with the board colour in mind. Natural kraft is not a neutral white printing surface, so lighter colours and some brand colours may reproduce differently. The printing method also depends on artwork coverage, colour requirements, board construction and the production specification.

Consider where branding needs to appear before adding print to every panel. A restrained exterior with a printed inside lid, for example, can create a different opening experience from full external coverage. Finishes should be treated in the same way: include them where they contribute to presentation, protection or a defined design objective.

05

When might another box style be more suitable?

Mailer construction is not automatically the right answer for every product. A folding carton may use less material for a lightweight retail item, while a shipping carton may be more appropriate for heavier goods or demanding distribution conditions. Premium gifting applications may call for a different presentation structure altogether.

Comparing the product, sales environment, packing process and delivery journey before selecting the box style prevents the structure from being chosen only because of appearance. The packaging should ultimately solve the practical requirements of the product first, with print and presentation developed around that structure.

From brief to finished packaging

How your packaging moves into production

Once the specification is agreed, the project can move through artwork preparation, production, finishing, quality checks and preparation for delivery.

01 DEFINE Specification

Confirm product dimensions, intended use, quantity, material and structural requirements.

02 PREPARE Artwork

Prepare and review artwork against the approved packaging dieline and print specification.

03 MAKE Production

Print, convert, assemble and finish the packaging according to the agreed production route.

04 CHECK Quality Control

Review the relevant structural, printing and finishing requirements before release.

05 COMPLETE Packing & Delivery

Prepare the finished packaging for handling, packing and the agreed delivery route.

See the complete custom packaging process
Compare packaging structures

Different structures can suit different products, presentation needs, protection levels and handling requirements. Compare related packaging formats to find the structure that best fits your specification.

Double wall tuck top Boxes
simple Double wall tuck top Boxes Compare structure →
Custom Kraft Full Flat Double Tray Packaging Boxes
simple Custom Kraft Full Flat Double Tray Packaging Boxes Compare structure →
Mobile Charger Packaging Boxes
simple Mobile Charger Packaging Boxes Compare structure →
Custom Sleeve Boxes 01
simple Sleeve Boxes Compare structure →
Prepare your brief

What should you send before we prepare your packaging?

You do not need to arrive with a finished technical specification. Start with the information you already have and identify anything that still needs to be decided.

NEED GUIDANCE? Product information is enough to start the conversation.

Send dimensions, photographs, artwork or an existing box reference where available.

01 / PRODUCT What is being packed?
  • Product dimensions
  • Product weight
  • Photograph or sample if useful
02 / PACKAGING What should the box do?
  • Required internal dimensions
  • Preferred box style
  • Material preference if known
03 / PRINT How should it look?
  • Logo and artwork
  • Brand colours
  • Finishing requirements
04 / PROJECT What should we plan around?
  • Required quantity
  • Delivery location
  • Required timing
Product questions

Kraft mailer box FAQs

Practical answers to common questions about dimensions, materials, printing and specifying Double Wall Tray & Lid Packaging Boxes.

Ask about your project
01 What are Double Wall Tray & Lid Packaging Boxes used for?

Double Wall Tray & Lid Packaging Boxes can be used for ecommerce, gifting, subscription, retail and other products where an integrated opening structure and useful presentation are required. The final suitability depends on product dimensions, weight, protection needs and the delivery environment.

02 Can mailer boxes be made to custom dimensions?

Yes. The dimensions can be developed around the product and any required insert or clearance. Measuring the complete product helps establish usable internal dimensions before the structural specification is prepared.

03 Which board is suitable for Double Wall Tray & Lid Packaging Boxes?

The appropriate board depends on box dimensions, packed weight, required rigidity, printing and handling conditions. Lightweight applications and ecommerce packaging can require different board constructions, so the product should be assessed before selecting a grade.

04 Can Double Wall Tray & Lid Packaging Boxes be custom printed?

Yes. Printing can be planned around the artwork, board construction and required colour result. Natural kraft is a brown printing surface, so colour appearance should be assessed differently from artwork printed onto white board.

05 Are Double Wall Tray & Lid Packaging Boxes suitable for shipping?

Some mailer specifications are suitable for ecommerce and delivery applications, but this depends on the board, product weight, dimensions and distribution conditions. More demanding shipping applications may require a stronger corrugated specification or another structure.

06 Can inserts be added inside a mailer box?

Inserts can be considered where they control movement, separate components, improve presentation or provide additional protection. Their dimensions must be included when calculating the usable internal space of the outer box.

07 How should I measure my product for a mailer box?

Measure the complete product at its maximum length, width and depth, including closures, accessories and protruding parts. Also account for any insert or protective material that will sit between the product and the box.

08 Can you help with the packaging dieline?

The dieline should follow the confirmed box dimensions and structure. If your project is still at an early stage, provide the product dimensions, intended use and artwork information so the structural requirements can be established first.

HAVE YOUR PRODUCT DETAILS READY?

Turn the product into a packaging specification.

Send your dimensions, quantity, preferred material, printing requirements and artwork status. If some of those details are still undecided, start with the product information you already have.

Request a Custom Quote +44 74 5340 5053
START WITH
01 Product
02 Dimensions
03 Quantity
04 Artwork
[email protected]
Scroll to Top