Mailer boxes have become one of the most trusted shipping solutions for retail brands, e-commerce sellers, subscription services, and small businesses. While logo printed mailer boxes are gaining popularity for branding, many companies still rely on standard brown kraft mailers because of their affordability.
Choosing between these two often comes down to balancing cost, brand value, and packaging performance. Understanding this comparison helps businesses make smarter decisions without compromising product safety or customer experience.
Understanding the Real Cost Difference
Many brands assume that colored or custom-printed mailers are significantly more expensive. However, the price difference is not always huge—especially when ordering in bulk. Colored mailers deliver stronger branding, and sometimes the small price increase delivers a much higher return through better customer experience.
In this section, we will discuss the main cost factors that influence the choice between colored boxes and brown mailers. For fair comparison, lightweight mailer boxes, eco-friendly mailer boxes, logo print options, and packaging sizes are also considered. This also includes one instance of your main keyword used naturally: logo printed mailer boxes.
1. Material Cost: Kraft vs. Premium White/Colored Stock
Material type plays the biggest role in pricing.
Brown Kraft Mailers
- Made from recycled kraft paper
- Naturally sturdy and cost-effective
- Ideal for small businesses that need affordable packaging
- No coating or lamination required
Cost Range: Lowest of all mailer box options
Colored Mailer Boxes
- Made from bleached white kraft or dyed paperboard
- Often include protective coatings
- More ink and paper treatments involved
Cost Range: Slightly higher due to printing surface and finishing needs
Key Insight:
If you need purely functional packaging, brown kraft is cheaper. But if your brand relies on visuals, colorful shipping boxes give a more premium feel at a reasonable increase.
2. Printing Design Costs
Printing impacts cost more than material.
Standard Brown Mailers
- Minimal printing required
- Single-color logos are extra affordable
- Simple layouts reduce ink usage
Colored Mailers
- Full-color external printing
- Inside printing options available
- Extra finishes add cost:
- Gloss laminate
- Matte finish
- UV coating
- Foil stamping
- Embossing/debossing
Cost Insight:
If you want multi-color designs, patterns, or brand storytelling, colored boxes are worth the investment.
3. Minimum Order Quantity (MOQ) Effects
Brown mailers have lower MOQs because they require less setup.
MOQ Comparison
- Brown mailers: Start as low as 50–100 units
- Colored mailers: Usually 100–500 units minimum
Why the difference?
Colored printing requires:
- Plate setup
- Ink calibration
- Additional production steps
Small brands can still choose colored boxes but may need higher-volume orders.
4. Shipping Costs
Your packaging choice affects shipping rates due to weight and dimensions.
Brown Kraft Mailers
- Often lighter
- Lower dimensional shipping weight
- Cheaper for regular shipments
Colored Mailers
- Slightly heavier due to coating or premium paper
- Not significantly heavier, but noticeable in bulk shipments
Cost Insight:
For large-volume shippers, even small differences in weight matter.
5. Customer Experience Value (CX ROI)
While brown mailers help cut costs, colored mailers offer branding benefits that directly impact sales.
Brown Mailer Customer Experience
- Simple, minimalistic, natural
- Often seen as eco-friendly
- Works for budget-conscious brands
Colored Mailer Customer Experience
- Eye-catching unboxing
- Stronger brand recall
- Useful for marketing-focused businesses
- Ideal for subscription boxes, boutiques, and luxury products
ROI Insight:
Colored mailers deliver higher perceived value, making products look premium—even if actual product cost is the same.
6. Eco-Friendly Factors Costs
Both options can be eco-friendly, but the cost varies:
Brown Mailers
- Naturally biodegradable
- Least chemical processing
- Cheapest eco-friendly option
Colored Mailers
- Can still be recyclable
- Vegetable-based inks reduce environmental impact
- Costs vary depending on coatings
If sustainability is your goal, brown kraft is the most cost-effective.
7. Which Option Should Your Business Choose? — A Quick Guide
Use this decision guide:
Choose Brown Mailers If You Want:
- The lowest possible packaging cost
- Lightweight mailer boxes for reduced shipping fees
- Minimalistic branding
- Eco-friendly, natural appearance
- Low MOQs
Choose Colored Mailers If You Want:
- Strong brand identity
- High retail appeal
- Premium customer experience
- Full-color storytelling panels
- Packaging that doubles as marketing
Cost Comparison Summary (Bullet Points)
Brown Kraft Mailers
- ✔ Lowest price
- ✔ Light and eco-friendly
- ✔ Minimal printing cost
- ✔ Fast production
- ✔ Ideal for small businesses
Colored Mailer Boxes
- ✔ Strong branding impact
- ✔ Enhances unboxing experience
- ✔ Versatile design options
- ✔ Great for e-commerce retail
- ✘ Slightly higher cost
- ✘ Higher MOQs
How to Reduce Costs for Both Packaging Types
- Order in higher quantities
- Reduce the number of print colors
- Choose standard sizes instead of custom die-cuts
- Keep designs minimal
- Skip internal printing unless necessary
- Use kraft materials for eco-friendly and cheaper options
Final Comparison: Are Colored Boxes Worth the Extra Cost?
Yes—if branding, visibility, and customer loyalty matter to your business. Colored mailer boxes convert packaging into a marketing tool. However, for purely functional shipping, brown kraft mailers remain cost-efficient and effective.
Where “custom design packaging” Fits Into Cost-Efficient Solutions
Whether you choose brown or colored mailers, the real savings come from thoughtful design choices, simplified print layouts, and optimized material usage. Working with experts in custom design packaging ensures:
- Smarter cost allocation
- Better material selection
- Design choices that reduce waste
- Packaging that aligns with brand strategy
A professional team specializing in custom design packaging helps you balance visual appeal and affordability—ensuring you never overspend on unnecessary finishes while still achieving premium results.
