Tear-Strip Zipper Mailer Boxes | Full-Colour Corrugated
- Material: E-flute, litho-laminated
- Structure: Tear-strip mailer, optional return strip
- MOQ: 100 pcs
- Lead Time: 10-15 days | Free dieline
Zipper Mailer Boxes with Full-Color Printing in food-safe folding board. Custom-printed, free dieline, MOQ 100 pcs.
Our Advantages
No Die and Plate Charges For Digital Samples
High quality printing
Quick Turn Around
Starting from 500pcs
Custom size and style
Competitive Price
Free Design Support
To door delivery
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COMPANY SERVICES
| Bigger Discounts Offer for large orders | Bigger Discounts Offer for large orders Prices are negotiable based on your purchase volume and Fixated prices can be offered based on frequency of the order. |
| After-service | Sample cost is refundable if it's not good quality as we promised!We will refund you the defected goods values as contract listed,if the defective goods are beyond as we contracted.Our goal is to have no bad feedback and keep doing business in the future! |
| Risk Free, Quality Assurance | We've Sate of the art production facility and all printed jobs are run through our strict quality assurance department, so there are no quality complaints. |
| Printed Method | We use Off-set printing to achieve excellent printing results. However, Digital and screen printing is also available depending on box requirements. |
| About Us | Guangzhou Ecopaperbox established in 2011 is undoubtedly an accredited manufacturer of custom boxes which are exactly according to the needs and desires of the clients. Our top priority is meeting the needs and requirements of our customers. Custom Packaging and printing are provided to the customers with excellent quality on the regular basis so that maximum benefit can be achieved in the minimum amount of time. All boxes that made of paperboard, we can produce. You are welcome to make inquiry via info@ecopaperbox.com and contact us at +8619927709433. |
What Is a Tear-Strip (Zipper) Mailer Box?
A tear-strip mailer, also called a zipper mailer, is a corrugated e-commerce box with a pre-cut perforated strip running around the front face. The customer pulls the tab and the box opens along a clean line without scissors, a knife or any risk of cutting the product inside. It is the format that turned unboxing from a chore into a brand moment, and it is now standard for subscription, beauty, apparel and DTC electronics.
The perforation is a precision job rather than a decoration. Cut too deep and the strip breaks in the courier network, so the box arrives already open. Cut too shallow and the customer tears the front panel apart trying to open it, which destroys the moment the strip was there to create. The tolerance is small and it is set by the flute and the liner, which is why the strip depth has to be specified rather than assumed.
Most zipper mailers also carry a second perforation and an adhesive strip for returns, so the same box reseals and goes back. For any category with a return rate above roughly 15 percent - apparel especially - that second strip removes the need to send a separate returns bag, which is both a cost and a packaging saving.
Which Industries Use This Box, and How It Is Specified
Zipper mailers are quoted by weight, print coverage and whether a returns function is needed.
| Industry / use case | How we normally spec it |
|---|---|
| Subscription boxes | E-flute with full-colour litho-laminated print inside and out, since the interior is the reveal. The tear strip is what stages it. |
| Beauty and cosmetics DTC | E-flute with a printed interior and a die-cut paperboard insert holding each item, so nothing shifts before the strip is pulled. |
| Apparel e-commerce | E-flute with a double tear strip - one to open, one with an adhesive lip to reseal for returns. Removes the separate returns bag entirely. |
| Consumer electronics | E-flute, because the contents are heavy and the tear strip must not compromise crush resistance. |
| Food and beverage subscription | E-flute with a moisture-resistant coating, tear strip positioned high so the contents are not exposed as the strip is pulled. |
| Corporate gifting and welcome kits | E-flute with an interior print and a ribbon or tissue layer, where the tear strip replaces the need for any tape at all. |
Tell us the packed weight. A tear strip is a deliberate weak line in the box, and above about 5kg it needs either a repositioned strip so the box does not fail in transit.
Material Specification
Flute choice on a zipper mailer is a compromise between print quality and the reliability of the perforation.
| Component / stock | Specification |
|---|---|
| E-flute (1.5mm) | The retail-facing flute. Takes litho-laminated or direct-print artwork cleanly and keeps the box slim. |
| E-flute (1.5mm) | More crush resistance for heavier or bulkier contents while still printing acceptably. |
| E-flute (4.5mm) | Used when the pack ships alone internationally or carries more than roughly 5kg. |
| Liner | White top kraft for full-colour print, or natural brown kraft for an unbleached recycled look. |
| Fluting medium | Recycled semi-chemical medium; the corrugated body is typically 70-100% recycled content. |
| Print method | Direct flexo for 1-3 spot colours, or litho-lamination when the artwork needs photographic CMYK. |
Sustainability notes
- Corrugated board is the most widely recycled packaging material in the world, with recovery rates above 80-90% in most developed markets.
- The fluting medium is typically 70-100% recycled fibre, and the liner can be specified as recycled kraft rather than bleached white.
- Water-activated paper tape and paper-based void fill keep the whole parcel in a single recycling stream - one plastic tape strip is enough to break that.
- Right-sizing the box removes both board and void fill, and usually lowers dimensional-weight freight cost at the same time.
- Direct flexo printing on natural kraft avoids the plastic film of a litho-laminated finish and is the lower-impact route when the artwork allows it.
Tear Strip, Print and Return Options
The strip position and the print coverage are the two decisions that define this box. Everything else is standard mailer construction.
| Option | What it changes |
|---|---|
| Tear strip position | Around the front face for a lid-lift reveal, or around the top edge for a full-open. Front-face is the more dramatic and the more common. |
| Double strip for returns | A second perforation plus an adhesive lip so the customer reseals and returns in the same box. Worth it above roughly a 15 percent return rate. |
| Interior print | Full-colour litho-laminated interior. On a subscription box this is the single highest-impact upgrade, because the interior is what is photographed. |
| Flute | E-flute for the best print and a slim profile, E-flute for heavier contents, E-flute above roughly 5kg. |
| Insert | Die-cut corrugated or paperboard insert holding each item in place, so the reveal is staged rather than a jumble. |
| Closure | The strip itself, plus tuck flaps. A properly cut zipper mailer needs no tape at all, which is a visible sustainability signal. |
A tape-free box is worth stating on the pack. Customers notice the absence of plastic tape, and it keeps the entire parcel in one recycling stream.
Printing and Finishing
- Offset CMYK - photographic artwork, gradients and product imagery.
- Pantone spot colour - exact brand colour matching, up to 6 colours plus varnish.
- Digital printing - the reason we can hold MOQ at 100; no plate cost on short runs.
- Hot foil stamping - gold, silver, rose gold, holographic. The most requested logo finish.
- Emboss / deboss - raised or recessed logo, with or without foil.
- Spot UV - gloss varnish over a matte laminate to pick out a logo or pattern.
- Finishes - matte, gloss, soft-touch, anti-scratch lamination or aqueous varnish.
Ordering: MOQ, Dieline and Lead Time
| Item | Detail |
|---|---|
| MOQ | 100 pcs per size and per design |
| Dieline | Free. We send a print-ready structural dieline to your designer before you commit to anything. |
| Pre-production sample | Plain structural sample in 3-5 days, printed sample in 5-7 days. Sample cost is credited against the bulk order. |
| Production lead time | 10-15 working days after artwork and sample sign-off |
| Artwork format | AI or PDF, CMYK, 300dpi, 3mm bleed, fonts outlined, placed on our dieline |
| Shipping | Ships flat-packed. Corrugated mailers are bulky assembled, so flat shipping is a real freight saving. |
Send the packed weight and the largest item dimension. The tear strip depth is calculated from the flute and liner combination, and getting it wrong in either direction is the one defect that ruins this format.
Technical Specifications
| Material | food-safe folding board, low-migration inks on request |
|---|---|
| Structure | Folding carton |
| Printing | 4-color offset / flexo; screen print available |
| Finish | matte or gloss lamination, spot UV, foil stamping on request |
| Sizes | fully custom – tooled from your dieline |
| MOQ | 100 pcs |
| Lead time | 7–12 working days after proof approval |
| Inks | low-migration, food-grade on request; ISO 9001 system |
Related Packaging
Other corrugated mailers
Drawer Sleeve Corrugated Boxes | Cosmetic Mailer with Handle | Custom Printed Shipping Boxes
Retail packaging that ships inside it
Rigid Gift Boxes | T-Shirt Box | Lipstick Boxes
Surface Choice
Our Guangzhou custom packaging factory runs four-color offset printing, automatic lamination, die-cutting and rigid box assembly on one floor. In-house production keeps lead times short and print color consistent from the first sample to full volume. Buyers are welcome to request a video tour or a factory audit before placing an order.
Packing Method For Corrugated Packaging:
Generally no need to put the PE bags inside of the cartons. Since the boxes are glued a layer of cardboard, generally production time is not long enough to dry the paper box. If you tie the PE bags, the steamed water pearl will be produced inside of the bags.
Product Details
- Custom sizes & shape – made to your exact dimensions, flute and box style.
- Eco-friendly board – recyclable corrugated / kraft material with low-migration inks on request.
- Secure closure – self-locking or magnetic options keep contents safe in transit.
- Full-surface printing – CMYK, Pantone, foil, emboss and spot UV available.
- Low MOQ & fast turnaround – start from 500 pcs, bulk pricing for 5,000+ units, 7–15 day lead time.
Customer Reviews
We ordered these zipper mailer boxes with full-color printing for our retail line and the print was sharp. Free dieline and fast tooling.
Solid zipper mailer boxes with full-color printing – the structure held up in transit and the finish looks premium on shelf.
Good communication and the MOQ of 100 worked for our small batch. We will reorder.
Frequently Asked Questions
What is a zipper mailer box?
A corrugated e-commerce box with a pre-cut perforated strip and a pull tab. The customer pulls the tab and the box opens along a clean line with no scissors and no risk of cutting the product. It is also called a tear-strip mailer or an easy-open mailer, and it is the standard format for subscription, beauty and apparel DTC because it turns opening the parcel into part of the product experience.
Will the tear strip break during shipping?
Not if the perforation depth is cut correctly for the flute and liner in use. The failure happens when a supplier applies a generic strip depth to any board. Too deep and the strip separates in the courier network so the parcel arrives open; too shallow and the customer destroys the front panel getting in. We set the depth from the actual board specification and prove it on the physical sample before production.
Can the same box be used for returns?
Yes, with a double tear strip. The first strip opens the box, the second exposes an adhesive lip so the customer folds it shut and sends it back. For apparel, where return rates commonly run 20-40 percent, this removes the need to include a separate returns bag - a saving in both cost and packaging weight on every single order.
Can you print the inside of the box?
Yes, and on a subscription or beauty box it is the upgrade with the highest return. The interior is what the customer sees at the moment of opening and it is what gets photographed and posted. Interior printing needs litho lamination rather than direct flexo, so it is specified at quote stage, not added later.
Is E-flute strong enough for a zipper mailer?
E-flute at 1.5mm gives the best print surface and a slim profile, and it suits contents up to about 2-3kg. For heavier or bulkier items we keep the E-flute wall and add a die-cut corrugated fitment or moulded pulp cradle, which carries the load without the extra freight volume of a thicker board. Above roughly 5kg, or for anything shipping internationally on its own, we also move the tear strip so it does not sit on a stress line.
Do I still need packing tape?
No. A correctly cut zipper mailer closes on its tuck flaps and seals with its own adhesive, so no tape is needed anywhere. That is worth printing on the box - it keeps the whole parcel in a single paper recycling stream, and customers notice the absence of plastic tape more than most brands expect.
What is the minimum order?
One hundred pieces per size and per design. Digital and short-run litho at that level means no plate cost, which is what makes a 500-piece corrugated mailer possible at all - most corrugated plants start at 1,000 or more.
