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Need a fast turnaround? Get an instant price quote for your rush order and meet your deadlines with ease.

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Know how much your custom made packaging will cost and get your branded boxes delivered at your doorstep.

Custom Mailer Boxes

Aly Packaging manufactures custom mailer boxes for Australian e-commerce brands, subscription services, and DTC retailers shipping products nationwide. A mailer box must survive multiple handling cycles, conveyor sorting, and stacking in delivery vehicles, which means corrugated strength, corner reinforcement, and secure closure are as critical as exterior branding. We specify single-wall or double-wall board based on product weight and fragility, with locking tabs that secure the box without tape. The finished mailer arrives structurally intact and visually intentional.

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Custom Mailer Boxes

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Benefits That Make Your Investment Worthwhile

At Aly Packaging, we go beyond the ordinary to help Aussie brands by providing various benefits that make every experience flawless.

Free Design Support

Make your dream packaging a reality with the help of our free design specialists.

Free Consultancy

Get honest, practical guidance from production specialists to make informed decisions.

Free Delivery

Forget the hassles of delivery and have orders delivered to your home for free.

Affordable Prices

Benefit from cost-effective, high-quality packaging solutions and make prudent financial choices.

Free Custom Quote

Get a free, personalised packaging quote by filling out the form. Unsure about materials or design? Our experts are here to guide you.

Every Question You Want Answered

Yes. Dimensions, board weight, print finish, and closure tabs are all specified against your product's weight, fragility, and the courier channel you ship through. We size mailer boxes to fit inside common Australia Post and StarTrack pricing brackets where possible, balancing protection against the dimensional weight surcharge that applies when the parcel exceeds size thresholds.

Minimum orders start from 50 boxes, which suits DTC brands testing a new size or small-batch fulfilment runs as well as established high-volume producers. Exact minimums are confirmed at quote stage based on board type and print finish.

Yes. We provide digital proofs and physical prototype samples at no charge before bulk production begins. Samples verify board strength, closure function, print colour accuracy, and that the finished box dimensions sit within your target courier pricing bracket.

Standard turnaround is 10 to 12 business days from artwork approval and approved samples. Rush turnaround is available in 6 to 8 business days depending on board stock, finish, and order quantity. Lead times are confirmed at quote stage.

 

Contact us at sales@alypackaging.com.au or call +61 4 8000 8551. Provide your target box dimensions, product weight and fragility level, estimated monthly volume, and preferred courier channel (Australia Post, StarTrack, Sendle). We return a quote within one business day.

Yes. Couriers charge based on weight and volumetric size. A mailer box that is 15mm larger in any direction increases the parcel's dimensional weight and can move it into a higher pricing tier. Over 100 shipments per month, this compounds into significant cost. We design mailer boxes to sit just below pricing boundaries.

Amazon Australia FBA requires mailer boxes to meet specific labelling, flap-closure, and durability standards. Coles and Woolworths—if you supply samples or gift sets for in-store promotion—have packaging compliance requirements. Priceline and Chemist Warehouse have different unboxing expectations for beauty and health products. We specify the box format to each channel's structural and presentation requirements.

A single mailer suits products without existing retail packaging and products that don't need inner cushioning during courier transit. Products that must arrive in branded retail boxes—luxury items, gift sets, or fragile goods—need an outer mailer. We assess your product during specification and recommend the structure that protects goods while minimising packaging weight and cost.

Testimonials of Our Loyal Customers

We at Aly Packaging are built on the foundation of our valued customers. Our client-centric approach allows us to deliver pin-perfect solutions and attain trust of brands across the nation. No matter what the business size, requirement, or budget is; we always endeavour to find a solution for every client.

Emma L.

“We needed custom candle boxes fast, and Aly Packaging pulled it off without a hiccup. The print quality’s spot on and delivery was quicker than expected — can’t fault them. Aussie brands need suppliers like this.”

Jack P.

“We’ve worked with Aly Packaging for over a year now. Whether it’s mock-ups, new product launches, or large runs, they’ve nailed every order. Proper service, great communication, and fair pricing - couldn’t ask for better.”

Chloe R.

“The design support was a lifesaver. Aly’s crew helped us create packaging that actually sells on shelves. Everyone who buys our skincare range comments on the box first!”

Jason W.

“We’re in the food industry and needed boxes that met local compliance but still looked premium. The Aly team understood exactly what we wanted. Fast quotes, solid samples, and the print colours matched perfectly.”

Liam B.

“We’ve used international printers before — but Aly Packaging AU gives the same high-end quality without the shipping drama or long lead times. Aussie-based and proud of it.”

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