Custom Tuck Top Mailing Boxes

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Anyone who sends out orders regularly knows that mailing days can get chaotic. You think you have enough boxes, then a rush of orders comes in and the packing table looks like a puzzle no one prepared for. Tapes go missing, labels peel, and someone always ends up folding boxes at the last minute. At Aly Packaging UK, our custom tuck top mailing boxes are designed to cater all these issues and ensure a seamless mailing pro. A good box should simplify the routine, not slow it down.

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What Makes Us The Top Supplier?

Top quality prints using the latest technology

We are commercial printers with experience in Litho,
Digital, and off-set printing techniques.

Fully Personalised sizes and designs

We specialise in manufacturing bespoke boxes in
custom size and shape of your choice.

Quick Turnaround

With our printing setups across the globe, we are
capable of handling small and bulk orders alike.

Flawless Finishing with Prime Results

Aly Packaging is mainly a B2B supplier, we believe in delivering the best of the best.

Dedicated Packaging Consultants

Our dedicated team of packaging consultants are
there to help you from start to finish.

Environmentally friendly production processes

Our eco- friendly cardboard, kraft, corrugated, and rigid boxes are produced in a controlled environment.

Customise Your Custom Tuck Top Mailing Boxes

Select Key Features & Finishes

Dimensions
Custom Sizes: We only manufacture bespoke boxes. You can order your custom printed boxes according to your preferred shapes and sizes.
Minimum Order Quantity
MOQ: The minimum order quantity you can expect from us is 50 Boxes.
Paper Stock
Paper Stock: 250Gsm to 500Gsm (14pt to 28pt) Eco-friendly White Card or Brown Kraft, B, C, or E-flute Corrugated, or 800Gsm to 1400Gsm Rigid Hardboard.
Printing
Printing Method: 1-4 Colour CMYK or Pantone Colours - Off-set, Digital, or Screen Printing – Outside or Both Sides
Sampling
Sampling: Free Digital Proofing. Material Sampling and Prototype Sampling is Provided on Demand.
Turnaround
Production Speed: Standard 10 Business Days, Priority 8 Business Days, Rush 6 Business Days.

Packaging That Makes Shipping Days Less Stressful

One thing that sets tuck top boxes apart is how easily they fold, but only when they are designed properly. If the creases are too stiff, the packer struggles. If they are too soft, the box feels flimsy when lifted. We shape our personalised tuck top mailing boxes in a way that the fold flows naturally without bending out of place. Some brands prefer a snug tuck that clicks into position. Others want a smoother closure so packing staff can move faster. The base might need extra strength for heavier items or reinforced edges if the products shift during delivery. These details may seem small, but they change how the packing process feels on a busy afternoon.

Materials That Survive Courier Handling

Mailing boxes need to deal with stacking, shaking, drops and temperature changes.

Cardboard: suitable for light items or flat products.
Kraft board: ideal for eco-focused brands or natural-themed packaging.
Corrugated board: the best choice for anything heavy or fragile.
Rigid board: used when mailing premium goods or gift sets.

All materials are FSC certified and printed using soy based inks. We use water based coatings to stop the surface from scuffing when boxes rub against each other during transit or warehouse handling. Matte finishes hide marks well and keep branding clear. Soft touch finishes create a smoother feel for higher-end mailing experiences.

Designs That Help the Box Work Harder, Not Just Look Nice

A mailing box rarely stays in perfect shape throughout its journey, so the design needs to compensate for that reality. We consider how the lid folds, how the sides lock, and how the box sits when stacked with others. If your brand sends out varied product sizes, we can adjust depth and width to keep items from rattling around. Some companies need boxes that hold tissue paper securely. Others want room for inserts or product cards. The opening motion also matters. A smooth tuck top makes unboxing feel more polished, especially for subscription kits or online stores that customers share on social media.

Optional Features

Reinforced edges for heavier products
Internal printing for brand messages
Spot UV for small details
Embossed logos
Custom inserts for keeping products steady
Protective coatings for courier handling

Experience Gained From Watching How Boxes Behave in Real Shipping

Most of what we know comes from observing what happens after the box leaves the packing table. Some boxes warp under pressure because the flaps were too long. Others open slightly during transport when the tuck is not tight enough. We have seen boxes collapse on the sides when handled by machines instead of people. These moments taught us how to adjust scoring depth, tuck length and panel structure so the box holds its shape. So whether you want your tuck top mailing boxes in auto-lock bottom style or in two-piece boxes style, we have the capability to help you in the best way possible.

Ordering That Fits Growing Stores and Busy Dispatch Teams

You can start with low order quantities to see how they fold, how they close and how they feel in hand. Once approved, production usually takes 8-10 working days, and UK delivery is free and insured. We can prepare digital proofs or physical prototypes so you can test them with actual products before committing to a full run.

Packaging That Supports Both the Brand and the Workflow

A good mailing box should make life easier for the people packing orders and give the customer a clean, reliable unboxing moment. At Aly Packaging UK, we build tuck top mailing boxes that hold their shape, fold smoothly and carry your products through shipping with confidence.Call: 07462 212 450 / Email: sales@alypackaging.co.uk