If you sell online food orders or gift deliveries, the box is the last thing your customer sees before they eat and the first thing they remember afterwards. We make custom food mailer boxes for online food brands, subscription services and businesses moving away from plastic that protect the food and do some of the marketing for you.
Self-locking mailer boxes survive courier handling and open like a present. Every box is made from food-grade board, cut to your dimensions and printed in full colour, spot colours or a simple one-colour logo, with orders from 100 units and delivery to Sydney, Melbourne, Brisbane, Perth and Adelaide and regional areas.
What our food mailer boxes are used for
- Online food orders: a box that photographs well brings free exposure on social media.
- Gift deliveries: the box has to hold its shape from the counter to the customer's table.
- Bakery mail orders: presentation matters as much as protection, so the print needs to be sharp.
- Sample packs: staff need a box that folds up fast when orders stack up.
Planning a range? Our guide, Custom Food Mailer Boxes in Australia: The Complete Buyer's Guide, goes into more detail.
Box styles
Choose the structure that suits the food and how your team packs it. We can also combine features or copy a box you already use.
- Roll-end mailer: A roll-end mailer locks without tape, survives courier handling and opens like a present.
- Mailer with insert: A roll-end mailer locks without tape, survives courier handling and opens like a present.
Sizes
These sizes suit most orders for food mailer boxes. Every box can be made to your exact inside dimensions.
| Popular size | Common use |
|---|---|
| 200 x 150 x 50 mm | online food orders |
| 300 x 220 x 100 mm | gift deliveries |
| 350 x 250 x 120 mm | bakery mail orders |
| Custom | Any size to suit your product |
Materials and board
We match the board to the weight of the food and how far it travels. The main thing to plan for with food mailer boxes is courier handling, stacking pressure and temperature swings in transit.
- Kraft paperboard: Unbleached kraft has a natural brown finish that suits rustic, organic and eco-minded brands. It prints best with bold one- or two-colour artwork, because the brown base shifts lighter colours.
- E-flute corrugated board: A thin corrugated board around 1.5 mm thick that adds crush strength and a little insulation while still printing cleanly. It is the standard for pizza boxes, mailers and heavier food orders.
- SBS paperboard: Solid bleached sulphate board gives a bright white surface for sharp, full-colour print. It is the usual choice for retail cartons and bakery boxes, and is commonly specified between 300 and 400 gsm depending on the weight of the food.
Food safety
All food mailer boxes are made from food-grade board. Where food touches the box directly, we recommend a barrier coating or liner, and print is kept on the outside. Our guide to food-safe packaging in Australia explains what the Food Standards Code expects from packaging.
Match the box strength to the courier journey and add void fill or inserts so contents don't shift.
Printing and finishes
Print your logo in one colour, match exact brand colours with Pantone, or go full colour with CMYK. Finishes include matte and gloss coatings, spot UV, foil, embossing and windows. Not sure which to choose? Read CMYK vs Pantone for food packaging and our guide to coatings and finishes.
Sustainable options
Kraft and recycled-content board, film-free windows and water-based coatings all help your food mailer boxes recycle more easily. We can add the Australasian Recycling Label to your artwork, and certified compostable options are available for some styles.
How ordering works
- Send your details: size, quantity and style.
- Receive a dieline and quote for your exact size.
- Add artwork, or ask us to lay out your logo. See how to read a dieline.
- Approve your proof.
- Production in 10–15 business days.
- Delivery flat-packed to Sydney, Melbourne, Brisbane, Perth and Adelaide and regional Australia.
Frequently asked questions
What is the minimum order for custom food mailer boxes?
Most styles start from 100 units. The price per box drops as quantity increases, so larger runs give better value.
How long does production take?
Production is typically 10–15 business days after you approve the proof, plus delivery time to your location in Australia.
Are your food mailer boxes food safe?
Yes. We use food-grade board and can add grease or moisture barrier coatings for direct food contact. Print is kept to the outside unless you request otherwise.
Can I get food mailer boxes in a custom size?
Yes. Every box is made to order. Send your inside dimensions and we draw a dieline to fit.
Can I see a sample before ordering food mailer boxes?
Yes. Plain samples help you test the fit, and printed proofs are supplied before production.
Get a price for your boxes
Send your size and quantity. We reply with a dieline and quote.
