Brown & Pratt Die Cut Mailer Boxes

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When you want to ship your products in attractive packaging that extends your company’s branding, it’s hard to beat the look and feel of a custom-printed die-cut mailer box. They have a much more upscale appeal to customers than the standard corrugated shipping box many businesses use and look a lot better than a poly mailer bag. If this type of box sounds like what you need to set your company apart, here is some good news: Brown and Pratt has more than 40 different cutting-dies for a range of different styles of mailer boxes in a variety of sizes. If one of them fits what you need, you’ll save both time and money on your custom-printed die-cut mailer box project.

What is a Die-Line Template?

Every custom shipping box project needs a die line template. Think of it like a blueprint for your mailer box—a 2D diagram showing what the box looks like before being assembled, meaning all flattened out. It shows all the essential details for making the box, including cut lines, fold lines, and perforation lines. If it’s going to be a custom-printed mailer box, the artwork can also be placed on the die line template to ensure it will fit as intended. One of the most common software programs used for creating and editing die line templates is Adobe Illustrator. Brown and Pratt is happy to provide design services if your company doesn’t have the right software or in-house graphic design capabilities needed.

How a Die-Line Template Works

There are three main types of lines shown on a mailer box die line template, including dotted perforation lines, cut lines, and fold lines. Depending on the specific type of box being made, the die line template might also show glue tabs and eye marks. These details on the die line template are critical to ensure the final physical layout of the mailer box is correct and meets your expectations. The die line template has multiple layers, which are important because the layers indicate the order of operations for creating the box. Typically, any needed perforations happen first, next are the cutting lines, and last but not least are the fold lines, which help guide the final assembly of the mailer box.

Why Choose a Die Cut Mailer Box?

Mailer boxes (also called pizza boxes, folding boxes, or subscription boxes) offer your company the chance to stand out from the competition with a more upscale approach to shipping packaging. Mailer boxes come in two primary styles:

  • Tuck Top Mailer Box: This type of mailer box has an extended outer flap with a lip that tucks down inside the box to close it. They are stylish and sturdy, making them a popular choice for a more sophisticated display of your products. They’re also easy to open.
  • Deluxe Mailer Box: Even more stylish than the tuck-top, these mailer boxes typically feature a thicker weight. The lip, rather than tucking down inside the box, rolls over the front and is secured with tabs that fit into vertical slots on the front. This type of box may also feature dust flaps on each side of the lid that tuck down inside the sides of the box, thus creating a more complete seal around the outer edges of the lid.

Make no mistake, a custom-printed mailer box from Brown and Pratt makes for shipping packaging worthy of unboxing videos after your customers receive their shipment. These boxes are far more likely than most packaging to be saved and reused by customers, thereby extending your branding over a longer period of time. Excellent add-on shipping items to consider combining with your custom printed mailer box include custom printed tissue paper and custom printed carton sealing tape.

If the mailer box you need will also include custom-printed graphics, the die line template is where you will see all the different panels where artwork can be placed. To ensure the artwork fits within the right boundaries without extending over areas that will be cut away or folded, the die line template will have a layer of additional lines, including the following:

  • Bleed Lines: These lines mark the physical edge of the material. If you need printing to go right to the edge, then the artwork (or at least the background) needs to extend slightly past the bleed line.
  • Trim Lines: These lines are placed to ensure there is at least an eighth of an inch buffer to prevent cutting off any essential graphic design artwork, text, and so on.
  • Crease Lines: These are also typically placed at least an eighth of an inch from crucial areas if you don’t want printed elements to end up on folding lines.

As you can see, the die line template is a critical element in creating a custom-printed die-cut mailer box. Brown and Pratt is ready to provide the assistance you need to create the die line template for your desired mailer box.

Custom-Printed Mailer Box Specifications and Quotes

image of box cutting die machine assemblyWhile die-cut mailer boxes can be created in any grade of corrugated, the most common board grades for mailer boxes are 200#E, 32B, 32C, 200#B, 200#C. The board used is usually just single-wall, but because of the way they are folded, assembled, and sealed, they end up being double-walled on three out of six sides. Printing of graphics, branding, messages, instructions, and more can be on both the outside and inside of the box. When printing on both the inside and outside, one side is typically only printed in one-color. Many customers choose to go with multi-color printing on the outside and single-color printing on the inside since the outside of the box will make the very first impression to the recipient.

If you’re looking to get a quote on custom printed mailer boxes, the process can be expedited if you know the following:

  1. Size: Inside dimensions of usable space needed.
  2. Color: Do you want the box to be 100% brown inside and out, white outside and brown inside, brown outside and white inside, or 100% white inside and outside?
  3. Printing: If the box will be printed, will it be printed on the inside, the outside, or both?
  4. Artwork:  What do you want to be printed on the box? How many ink colors are needed?
  5. Quantity:  While there is no real minimum order, the cost per unit does go down with larger quantities, with price breaks occurring at quantities of 500, 1,000, 1,500, 2,000, and so on.

How Does Brown & Pratt Save Time and Money with Cutting Dies?

Producing custom printed die-cut mailer boxes in bulk requires a cutting die specific to the box type and size, the die line template, and printing plates. The cost of a cutting die can range anywhere from $600 to $2,000+ per mailer box size. Over the years, Brown and Pratt has acquired, purchased, or inherited more than 40 different cutting dies for various sizes of die-cut mailer boxes. If one fits your project, you could save up to $3,000 in labor and material costs of producing a new cutting die. Our available cutting dies all have specific features and board grades that must remain unchanged. For example, if a cutting die was created for an 8x8x4 deluxe mailer box made of 200#B corrugated board, it can only be used for boxes meeting those exact specifications. Clearly, it’s worth finding out if we have a cutting die template for your project! After all, why reinvent the wheel if we already have something that fits your needs and can potentially save you thousands of dollars on your first order?



3 X 3 X 21 1/2 8 x 8 x 1 1/4 13.5 X 10.5 x 3
5 1/2 x 3 1/2 x 2 1/2 8 3/4 x 8 3/4 x 2 3/4 13 X 11 X 5.5
5 x 4 x 3 1/2 9 X 5.75 X 4.375 15 x 11 x 4
5 X 5 X 2 9 X 9 X 4 16 X 10 X 5
6 X 5 X 4 10 X 8 X 4 16 x 12 x 4
6 x 10 x 3 1/2 10 x 6 x 3.5 16 x 15 x 5
7 x 5 1/4 x 2 1/2 10 X 10 X 2 17 x 11 1/2 x 7
7 x 7 x 3 11 X 9 X 4 18 x 6 x 6
7.25 X 5.5 X 2 11 X 11 X 11 20 X 7 X 7
8 X 6 X 1.875 12 X 6 X 2 20 x 12 x 4
8 X 6 X 4 12.25 X 6 X 4 21 X 15 X 5
8 1/2 x 7 x 3 1/2 12.5 X 10.5 X 1.5 25.125 x 3.375 x 3.375
8.25 X 8.25 12.5 X 9.25 X 4.25 54 X 10 X 4
8.5 x 6 x 3 12 X 12 X 6
8 x 8 x 1 1/4 13.5 X 10.5 x3


Brown & Pratt: Your Partner for Custom Packaging and Shipping Supplies

We’ve been providing custom packaging and shipping supplies to a wide range of businesses for nearly 70 years. We leverage this deep expertise to get the results you need, and we’ve built our reputation on an unfailing commitment to excellence in customer service, which means we collaborate with you every step from start to finish on every project. If you’re ready to start working with a custom packaging and shipping supplies partner who can meet all your needs, then it’s time to contact Brown and Pratt. Reach out to us through the Contact page of our website, call us at 888-659-9450, or fill out our online Request a Quote form. We look forward to working with you!

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