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Custom Single Wall Cardboard Boxes

Online shops, subscription brands and fulfillment teams use these boxes for parcels that travel one at a time, where every millimetre of depth affects postage. The key choice is the flute, E for slim printed mailers or B and C for more cushioning, sized to your product and your usual postage band.

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Which flute should a single wall mailer use: E, B or C?

Aly Packaging manufactures single wall cardboard boxes for UK online retailers, subscription brands, fulfilment houses and small manufacturers. Every single wall box has one fluted layer between two liners, so the flute is the decision that matters. E-flute, about 1.5mm, folds into neat mailers with sharp print and saves depth for postage bands. B-flute, about 3mm, is the general shipping choice for books, homeware and boxed electronics. C-flute, about 4mm, cushions better but takes more warehouse space. We choose from product weight, fragility and courier service, then sample the shortlist so you can compare them side by side.

Every spare centimetre is paid for twice, in postage and in void fill

Oversized cartons cost money in two places. Royal Mail prices by size band: a Large Letter must stay within 2.5cm deep and 750g, and a Small Parcel within 45 x 35 x 16cm and 2kg, so a mailer just over either line moves up a price. Many couriers also bill bulky parcels by volumetric weight, which effectively charges for air, and Evri and DPD each set their own size limits. Right-sizing fixes both problems. Internal dimensions are set from the packed product plus a small clearance, which removes most void fill and stops items moving in transit. Ranges with many products can often share two or three box sizes and a simple insert, which costs less than a separate carton for each item. Send a packed sample or exact dimensions and we will check the band before quoting.

Shipment packaging under EPR: why your mailer counts as household waste

Online sellers sometimes treat the outer box as a trade matter, then find it carries household fees. Under the UK Extended Producer Responsibility for Packaging Regulations 2024, packaging on goods sent to consumers is reported as shipment packaging and normally classed as household, with fees charged by material and weight and set to reflect recyclability. A plain single wall mailer is the simpler box to report: one corrugated material, water-based flexo or digital print, and paper tape instead of plastic. Brown kraft hides scuffs and suits one-colour logos, while a white-top liner shows brand colours more accurately for a modest extra cost. Board grade and box weight for each size go on the specification before production begins, so the weights in your submission come from the actual carton.

Versatile Styles for Any Need

Single wall cardboard adapts to a variety of box styles. Popular formats include:

  • Tuck-top boxes with self-locking flaps for easy assembly

  • Roll-end cartons for high-speed packing lines

  • Crash-lock bases for fast setup and secure bottoms

  • Gable-topped cartons for retail grab-and-go displays

Custom die-cuts, hand-holds and perforations can be added for convenience and functionality. This versatility makes single wall boxes suitable for e-commerce shipments, retail boxes and in-store displays, especially when using Single Wall Cardboard Boxes With Custom Logos.

Materials

  • E-flute single wall, about 1.5mm, for postal mailers and printed retail cartons
  • B-flute single wall, about 3mm, for general shipping and boxed goods
  • C-flute single wall, about 4mm, where cushioning matters more than depth
  • Kraft or white-top liners, closed with paper tape for a single-material box

Finishes

  • Uncoated kraft with one or two-colour water-based flexo
  • Digital print for short runs and seasonal designs
  • Inside print for unboxing messages and returns instructions
  • Matte aqueous coating for light scuff resistance in transit
  • Tear strips and second adhesive strips for easy opening and returns

Product size, weight and postage band are enough to start

Send the packed product dimensions and weight, your usual postage band or courier, the quantity and any artwork. Online retailers, subscription brands, fulfilment houses and marketplace sellers then receive a recommended flute and box style, with internal sizes checked against carrier limits and box weights listed for EPR. A new size can be tested at low minimum quantities before you switch a whole range. Standard turnaround is 10 to 12 business days from artwork approval, with a rush option in 6 to 8 business days. Contact us at sales@alypackaging.co.uk or call +447462212450.
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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 Single Wall Cardboard 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.

Rush Order Service

We truly understand that everything is not standard so our expedited plan of 04 working days is the solution to your rush requirements. Fill below form and get instant response from one of our packaging experts.

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