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Orange Mailer Boxes

Orange is the color that fails most often in packaging print. The reason is simple enough. Four color process has cyan and magenta and yellow and black in it and no orange pigment anywhere. Every orange on a standard press is therefore built by overlapping magenta dots on yellow dots.

We make custom orange mailer boxes at The Customized Boxes for food brands, sports labels, hardware sellers and subscription services. Getting a brand orange onto corrugated is a press decision rather than a design decision. Our minimum order is 100 boxes per size and design, we provide shipping free across the United States. We do not charge setup or tooling fees on any order.

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We can rely on TheCustomizedBoxes without worry. Also the boxes are super crisp and high quality. 10/10 recommend!

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Competitive pricing and quick turnaround time. I get my delivery as promised and likely to work with them again!

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The quality of the boxes surpassed my expectations, and I couldn’t be happier with the outcome.

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For Custom Boxes

Working with Jon was wonderful. Boxes turned out excellent. I’ll be working with them for all my box printing needs.

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Get Custom Quote


  • Custom Sizes Built around your product
  • MOQ 100 Boxes Per size, per style
  • Free Design Support Every file checked
  • No Setup Charges No die or plate fees
  • 8 to 10 Day Turnaround After dieline approval
  • Free US Shipping Across the US

Why Does Orange Never Match the Brand Color?

Because the brightest oranges sit outside what four color process can physically reach. Around 40 percent of Pantone Solid Coated colors cannot be reproduced in CMYK at all and vivid orange is one of the worst affected families. Color references name PMS 021 and PMS 165 and PMS 1505 as examples that process printing cannot hit.

A spot ink reaches those colors because the pigment is mixed to that shade before it ever touches the press. Process printing has to build the same shade from two transparent inks stacked on top of each other and that is where the brightness disappears. Our guide to CMYK and how it converts walks through what happens to a color during that conversion.

Spot Orange or CMYK Orange for a Mailer Box?

Ink systems for an orange mailer box
Method What you get When to use it
Pantone spot ink The exact brand orange, run after run Brand critical packaging and repeat orders
CMYK process A duller orange that drifts between runs Full color artwork with photography
CMYK plus a spot orange Photography and an accurate brand orange Designs that need both at once
Digital extended gamut Closer than plain CMYK, still short of spot Short runs under a few hundred boxes

Does the Board Change How Orange Prints?

It changes it completely. Orange printed on bleached white liner comes out bright because the sheet reflects light back through the transparent ink. The same orange on natural kraft turns rust brown because the brown board absorbs the light instead of returning it.

A white undercoat printed first fixes this on kraft, though it adds a print pass and covers the kraft texture. Brands that want both a strong orange and a natural look usually put the orange on a white printed panel and leave the rest of the box bare.

Which Board and Flute Should an Orange Mailer Use?

Board and flute for an orange mailer box
Specification What we run
Liner Bleached white outer for color accuracy, kraft with a white undercoat as the budget route
Flute E flute at about 1.6 mm for retail weight, B flute at about 3 mm for heavier goods
Board strength 32 ECT for standard ecommerce shipments
Print method Flexo with a spot ink station for volume, digital for short runs
Coating Matte or gloss lamination, and aqueous coating on budget runs

Which Related Mailer Page Do You Need?

Related mailer box pages
What you are after Where to go
The full mailer range and structures Custom Mailer Boxes
Any other brand color on a mailer Colored Mailer Boxes
The brightest possible print surface White Mailer Boxes
A high shine laminated finish Glossy Mailer Boxes
Board grades and flute detail Corrugated Mailer Boxes

Minimum Order, Lead Time, and Samples

  • The minimum order is 100 boxes per size, so a two size range starts at 200 boxes
  • Production runs 8 to 10 business days after you approve the dieline
  • A plain sample takes 3 to 5 business days and a printed sample takes 7 to 10
  • Price breaks land at 500 and 1,000 units on the same artwork
  • Repeat orders reuse the die we already hold so nothing changes on the setup side

Request a Quote

Send us your product dimensions and your run quantity and your Pantone number. We will tell you whether the color is reachable in CMYK. Then we quote the spot ink alternative on the same size so your decision rests on real numbers.

Size Any custom size, built from your packed product dimensions
Material Bleached white liner for color accuracy, or kraft with a white undercoat
Color Scheme Pantone spot orange for brand accuracy, CMYK process, or CMYK plus a spot station
Color Limitation Vivid oranges such as PMS 021, 165 and 1505 sit outside the CMYK range and need a spot ink
Coatings Aqueous coating, gloss or matte lamination
Finishing Options Spot UV, foil stamping, embossing, debossing
Flute E flute at about 1.6 mm for retail weight, B flute at about 3 mm for heavier goods
Board Strength 32 ECT for standard ecommerce shipments
Box Structure Roll end tuck top mailer, roll end front tuck, or a full die cut mailer to your dieline
Artwork Vector PDF or AI on our dieline, 3 mm bleed, Pantone identified
Minimum Order 100 boxes per size
Price Breaks 500 and 1,000 units on the same artwork
Estimated Price Range $0.80 to $3.90 per box. An estimated range that moves with size, board grade, print coverage and finish
Box Sample Flat View, 3D Mock-up, Physical Sampling (On Demand)
Setup and Tooling We do not charge setup or tooling fees. The die and the printing plates are included in your unit price, on the first order and on every one after it
Turnaround Time 8 to 10 business days after you approve the dieline
Shipping Free across the United States
How To Order

How To Order Custom Boxes

Four steps from your first message to boxes on your dock. There are no setup or tooling fees at any stage, and delivery is free across the contiguous US.

  1. Tell Us About Your Product

    Send your product size, the packed weight and the quantity you need. We recommend the board grade and box style that fit, then quote a unit price with no setup fee.

  2. Approve Your Dieline

    Upload artwork as a vector PDF or AI file and we check it against our artwork guidelines for bleed, resolution and Pantone colors. If you have no artwork yet, our team draws it on our dieline for you.

  3. Check a Real Sample

    A plain structural sample takes 3 to 5 business days and a printed sample takes 7 to 10. You hold the actual box before the full run starts.

  4. Production and Free Delivery

    Production runs 8 to 10 business days after you approve the dieline. We pack your boxes and deliver them free across the contiguous US, with export orders quoted separately.

Start Your Quote

Minimum order is 100 boxes per size. Price breaks at 500 and 1,000 units.
Or build your own dieline first on our free dieline generator.

Build Your Dieline Free, Before You Order

Most suppliers send a dieline after you place an order. Ours is a live tool on this site. Pick a box style, type your own dimensions and download the file in a few seconds, with no account and no charge.

The Customized Boxes Download
Reverse Tuck End
reverse tuck · dust flaps Unit
mm cm in
Size
120120–200 6030–60 160100–550
Material Cardstock SBS (White) Generate
Details Ready to download. inside119.4 × 59.4 × 158.9 mm outside120.4 × 60.4 × 160.9 mm sheet375.5 × 309 mm boardSBS · 0.5 mm
CutCreaseBleed
Reverse tuck end dieline, 120 x 60 x 160 mm, from our generatorRed lines are cut, blue dashed lines are crease and the green outline is the bleed edge.
Sheet 375.5 × 309 mm Die 120 × 60 × 160 mm

Open the Dieline Generator

Every box style we make is in the tool, at any size you type. Exports to AI, PDF and SVG, and our design team checks your artwork on that dieline free of charge.

Orange Mailer Box Questions Buyers Ask

The answers below cover ink systems and board choice and color consistency. Send us your Pantone number if your question is not here and we will tell you what the press can reach.

Why does my orange mailer box look duller than my brand color?

Your brand orange is probably a Pantone spot ink and the box was probably printed in CMYK. Process printing has no orange pigment in it, so orange gets built from magenta and yellow dots layered together. That build loses saturation and the brightest Pantone oranges sit outside the process range entirely.

Which Pantone oranges cannot be printed in CMYK?

Vivid oranges such as PMS 021 and PMS 165 and PMS 1505 are the standard examples that process printing cannot reproduce. They are part of the roughly 40 percent of Pantone Solid Coated colors that fall outside the CMYK range. Running those colors as a spot ink is the only way to reach them on press.

Is a spot color orange more expensive than CMYK?

The ink itself costs more and the press needs a station dedicated to it. On a repeat order that cost spreads across the run and often lands close to the CMYK route. We quote both so you can see the real difference on your own quantity rather than on a general rule.

Can you print orange on a brown kraft mailer box?

Yes it prints, but the brown board pulls the orange toward rust and takes the brightness out of it. A white undercoat printed under the orange restores most of that brightness at the cost of an extra print pass. Bleached white liner remains the most accurate surface for any bright color.

Will my orange mailer boxes match on the next reorder?

A Pantone spot ink matches closely from run to run because the pigment is mixed to that shade every time. CMYK orange drifts more between runs because it depends on how four separate inks lay down on the day. Brands that reorder regularly should specify a spot ink for the orange.

What flute do you use for an orange mailer box?

E flute at roughly 1.6 mm is standard for retail weight mailers and keeps the printed face flat enough for solid color coverage. B flute at roughly 3 mm goes on heavier shipments where crush resistance matters more than print quality. Solid orange coverage shows flute lines more than a light design does, so E flute is the safer choice for full color boxes.

Free of charge

Hold the Box Before You Commit

A quote is easy to compare on a screen. A sample is the only thing that tells you how the board feels in the hand and whether your product sits the way you expect. We send samples free, and you can pick the one that answers your question.

  • Plain Sample Unprinted, so you can judge the structure, the board and the fit around your product. 3 to 5 business days
  • Random Sample A box from recent production, so you can see our print quality and finishes in the hand. Ships from stock
  • Printed Pre-Production Sample Your own artwork on your own board, exactly as the run will be printed. 7 to 10 business days

Order a Sample Box

A flat view and a 3D mock-up come free before anything prints. Already know what you need? Get a quote instead.