How Many Custom Mailer Boxes Are Produced in the U.S. Each Year

Imagine the thrill and excitement of a package arriving in a sleek, beautifully branded mailer box. For most customers, first impressions are important, and when they receive that box, the sturdiness, feel, and eye-catching design pretty much sets the tone for how trustworthy the brand is.

That’s why businesses continue to choose mailer boxes: they’re reliable, presentable, and designed to impress. Their rise in popularity reflects how important the unboxing experience has become. Which leads to a curious thought — just how many mailer boxes are produced in the U.S. each year?

What are the Numbers?

Mailer boxes are quickly becoming a staple in the U.S. packaging scene. In 2023, the country shipped 384 billion square feet (BSF) of corrugated packaging, with projections pushing that figure to 432 BSF by 2028. [1] While that includes all kinds of boxes, mailer boxes are carving out their own space. They make up about $1.3 billion of the U.S. market and are growing at a steady 7% each year, outpacing the broader box market’s 1–2% growth rate. [2]

Globally, the demand for corrugated boxes is also rising. The overall market is expected to grow from $180.26 billion in 2025 to $269.19 billion by 2033. [3] Specifically, the corrugated mailer segment is forecasted to nearly double — from $4.18 billion in 2023 to $9.07 billion by 2034. [4] The U.S. holds about 37% of that market, making it a major player in the rise of mailer packaging. [2]

Why the Increase?

Explosion of Online Subscriptions

Subscription services have become a major driver for mailer boxes getting its boost. Beauty products, meal kits, curated services, and even mystery box services are becoming affordable options, and the eye-catching, branded packaging creates a memorable unboxing experience for many.

According to industry sources, the subscription box market is projected to grow to $87.06 billion by 2029, with a compound annual growth rate (CAGR) of 20.1%. [5] As this model expands, the need for mailer boxes will grow alongside it.

E-commerce and Shipping Convenience

The COVID-19 pandemic played its part in fast-tracking the growth of online shopping. In 2020 alone, global e-commerce sales soared to $26.7 trillion, with U.S. e-commerce revenues reaching $9.6 trillion. [4] This surge pushed brands to find more efficient packaging solutions. The lightweight, pre-scored, and easy-to-assemble mailer boxes became the go-to choice for fast, efficient shipping and customer fulfillment.

Sustainability Trends

Mailer boxes also meet the growing demand for eco-friendly packaging. 96% of all corrugated boxes in the U.S. are recovered for recycling [6], and roughly 75% are made from recycled materials. [7] This makes mailer boxes a sustainable choice that supports both environmental goals and customer expectations.

Mailer boxes continue to show promise with their steady growth, and with online shopping and subscription boxes still going strong, the demand won’t be slowing down anytime soon. Still, it’s important to note that mailers are just one part of the bigger packaging picture.

The shipping industry requires different kinds of packaging for promotion, product safety, and convenience. Try rotating your custom mailers with sturdier shipping boxes, sleek rigid boxes, or anything in between. The key is finding what works best for your brand and your customers.