Custom Mailers & Branded Packaging
find it. love it. keep it.
Find it. Love it. Keep it. Branded mailers and packaging are where the unboxing moment lives — the corrugated mailer on the doorstep, the tissue paper that crinkles open, the belly-band holding the story together.
Find it. Love it. Keep it. Branded mailers and packaging are where the unboxing moment lives — the corrugated mailer on the doorstep, the tissue paper that crinkles open, the belly-band holding the story together. Sense2 has been designing custom packaging for Australian agencies, brand teams and retailers for 30 years, with thousands of 5-star Google reviews and an in-house design studio that treats the opening moment as the campaign's most photographed asset.
Find it fast
- Typical MOQ:
- 100-500 for printed mailers and rigid boxes; 250-1,000 for custom tissue paper and tape
- Lead time:
- 10-20 business days standard; 5-10 day express available on corrugated mailers and stock-shape rigid boxes
- Branding:
- full-colour digital print, offset, 1-4 colour flexo, foil stamp, spot UV, deboss, tone-on-tone and screen print
- Materials:
- FSC-certified kraft and corrugated board, recycled pulp, rigid greyboard, rPET void fill, honeycomb paper wrap, acid-free tissue
- Price range (250qty, printed corrugated mailer):
- AU$2.40-$6.80 per unit; rigid magnetic-close box AU$8-$28
- Free samples Australia-wide, dispatched within 48 hours from our Sydney warehouse
Best for
Choose custom mailers & branded packaging if your moment is e-commerce unboxing & dtc launches, pr & influencer seeding packs or staff onboarding & culture kits.
E-commerce unboxing & DTC launches
Printed corrugated mailers in brand colour, with a tissue paper layer and a branded sticker seal — the three-layer reveal is what makes the TikTok. Pair with a thank-you card on uncoated stock for tactile contrast.
PR & influencer seeding packs
Rigid magnetic-close boxes with foam or honeycomb cradle, soft-touch laminate, foil-stamped logo and a custom belly-band. The box becomes the desk keepsake long after the product is photographed.
Staff onboarding & culture kits
Kraft mailer boxes with tone-on-tone printed tissue, a welcome card and a branded sticker set — sent to home addresses for distributed teams. We kit, pack and dispatch nationwide from our Sydney warehouse.
Retail gift-with-purchase & in-store packaging
Printed carrier bags, rigid shoulder-lid boxes and branded tissue in seasonal colourways. FSC paper and soy inks keep the sustainability story credible at the counter.
Conference & speaker gifting
A custom rigid box with a debossed linen wrap, ribbon pull and printed insert tray turns a speaker gift into the weekend's most-posted moment — and the box stays on the desk.
“Our PR boxes arrived the week before launch and the unboxing videos went up across the fashion press within 48 hours. The foil deboss was exactly what we'd sketched in the mood board — the Sense2 team understood the register beautifully.”
“We reorder our seasonal mailers with Sense2 every quarter. They remember our Pantones, they remember our dieline, and the tissue paper always lands in the right colourway for the campaign. The team makes it feel effortless.”
“The welcome-kit mailers went out to 340 new starters across three states and every one of them landed on the week we'd promised. Considered at every touchpoint — from the dieline to the delivery note.”
Compare your options
| Use case | Our recommendation |
|---|---|
| E-commerce unboxing & DTC launches | Printed corrugated mailers in brand colour, with a tissue paper layer and a branded sticker seal — the three-layer reveal is what makes the TikTok. Pair with a thank-you card on uncoated stock for tactile contrast. |
| PR & influencer seeding packs | Rigid magnetic-close boxes with foam or honeycomb cradle, soft-touch laminate, foil-stamped logo and a custom belly-band. The box becomes the desk keepsake long after the product is photographed. |
| Staff onboarding & culture kits | Kraft mailer boxes with tone-on-tone printed tissue, a welcome card and a branded sticker set — sent to home addresses for distributed teams. We kit, pack and dispatch nationwide from our Sydney warehouse. |
| Retail gift-with-purchase & in-store packaging | Printed carrier bags, rigid shoulder-lid boxes and branded tissue in seasonal colourways. FSC paper and soy inks keep the sustainability story credible at the counter. |
| Conference & speaker gifting | A custom rigid box with a debossed linen wrap, ribbon pull and printed insert tray turns a speaker gift into the weekend's most-posted moment — and the box stays on the desk. |
Make it a Brand Kit
Pair these together for a coordinated rollout — we’ll kit, brand and deliver everything together.
DTC Launch Unboxing Set
full-colour printed corrugated mailer, custom tissue paper in brand Pantone, branded sticker seal, thank-you card on uncoated stock and shredded kraft void fill
Best for: E-commerce brand launches, subscription-box first drops, DTC brand refreshes
From AU$6.80 per complete set at 500qty
PR Seeding Rigid Box
rigid magnetic-close box in soft-touch laminate, foil-stamped logo, custom foam or honeycomb cradle, printed belly-band and ribbon pull
Best for: Influencer seeding, press drops, VIP campaign moments
From AU$18-$42 per complete set at 250qty
Culture Kit Mailer
kraft corrugated mailer box, tone-on-tone printed tissue, welcome card, branded sticker sheet and a single featured merch piece (tote, notebook or drink bottle)
Best for: Staff onboarding, remote-team culture drops, people & culture programs
From AU$14-$28 per complete kit at 250qty, depending on merch inclusion
Find it. Love it. Kit it.
How to choose
Start with the moment, not the material — that's the part of a packaging brief we enjoy most. If the box is the unboxing hero (PR seeding, premium gifting, brand launch), step into rigid greyboard construction with a magnetic close, soft-touch laminate and a foil or deboss finish. The weight in the hand is what makes the recipient slow down. If the box is a transit-plus-reveal (DTC e-commerce, subscription, staff kits), a printed corrugated mailer does the heavy lifting beautifully — full-colour exterior, one-colour interior print, and a tissue-paper layer to make the opening feel considered. Print method drives both cost and character. Flexo is the most economical way to carry a bold logo on corrugated; it's what you want for 1,000+ unit runs. Digital print is the hero for short-run, full-colour, photographic or variable-data packaging — agencies love it for campaign-specific SKUs and personalised mailers. Offset gives the sharpest CMYK on rigid-box wraps. Foil stamp, spot UV and blind deboss are the finishes that make a rigid box feel like a gift — use them sparingly, on one hero element, for the best effect. Material is where the sustainability story either lands or doesn't. FSC-certified kraft and recycled corrugated are our default substrates — they carry the eco narrative without needing a press release. For void fill we route agencies away from polybeads and toward honeycomb paper wrap, shredded kraft or rPET film. Acid-free tissue paper in a custom Pantone is the most cost-effective way to extend brand colour into the unboxing without re-engineering the box itself. On MOQ: printed corrugated mailers start at 100-250 units; rigid boxes from 250-500. Custom tissue paper and branded tape typically start at 500-1,000 because of print-cylinder economics. Stock-shape mailers with a printed sticker seal are the smart move for pilots under 100 — same unboxing impression, a fraction of the tooling. Finally, always prototype. Forty-eight hours for a stock sample; 7-10 days for a white-mock of your custom dieline with artwork applied. The creative director holds it, folds it, photographs it under the studio lights, and the final approval is easy. Fast can still feel thoughtful — that's the standard our agencies run with us.
Pricing guidance
Pricing rule of thumb: at 250 units, a printed corrugated mailer (1-colour flexo exterior) sits around AU$2.40-$4.20; full-colour digital print AU$3.80-$6.80. Rigid magnetic-close boxes with soft-touch laminate run AU$8-$28 depending on size and finish. Custom tissue paper (1-colour, 500qty) AU$0.35-$0.75 per sheet. Branded tape AU$2.80-$5.50 per roll at 250qty. Foil stamp adds AU$0.45-$1.20 per unit; spot UV AU$0.30-$0.80. Dieline and tooling setup AU$180-$650 once-off, depending on box complexity.
Delivery across Australia
Delivered Australia-wide in 10-20 business days standard — Sydney, Melbourne, Brisbane, Perth, Adelaide, Hobart and Canberra daily. Express 5-10 day turnaround available on corrugated mailers and stock-shape rigid boxes for late briefs. Free shipping on orders over AU$500. We kit, split-ship to multiple venues, warehouses or home addresses, and run timed-release dispatch for launch windows at no extra handling — from our Sydney warehouse and Byron Bay head office.
Why Sense2
- ✦30 years of packaging briefs — trusted by Australian agencies, retailers, government departments, universities and independent fashion houses for considered unboxing that photographs beautifully
- ✦In-house design studio for dielines, mockups, 3D renders and pre-production samples — so your creative team can hold the weight and check the print register before artwork lock
- ✦thousands of products in the catalogue including stickers, tape, tissue, ribbon, hang tags, void fill and kitting inserts — one brief, one PM, one on-time delivery
- ✦Sustainability, done credibly — FSC paper, recycled kraft, soy-based inks, rPET void fill, lower-ink packaging and plastic-free options across the range
Frequently asked questions
What's the minimum order for custom mailers and packaging?▾
Printed corrugated mailers typically start at 100-250 units; rigid magnetic-close boxes from 250-500. Custom tissue paper and branded tape start at 500-1,000 because of print-cylinder economics. For pilots under 100, we'll route you to stock-shape mailers with a printed sticker seal — same unboxing impression, a fraction of the tooling.
How long does custom packaging take to produce and deliver in Australia?▾
Standard lead time is 10-20 business days from artwork approval for printed corrugated and rigid boxes. Express 5-10 day turnaround is available on corrugated mailers and stock-shape rigid boxes. Custom tissue paper and tape follow a similar window. For late briefs, talk to our team — we've landed launch-week packaging more times than we can count across 30 years.
What print and finishing methods do you offer on branded packaging?▾
Full-colour digital, offset, 1-4 colour flexo, foil stamp (gold, silver, rose gold, holographic), spot UV, blind deboss, tone-on-tone and screen print. Soft-touch laminate, matte laminate and uncoated finishes available on rigid-box wraps. Setup is AU$180-$650 once-off depending on dieline complexity; finishes add AU$0.30-$1.20 per unit.
Can I see a sample of my custom box before production?▾
Yes. Stock-sample packaging ships Australia-wide within 48 hours from our Sydney warehouse. White-mock prototypes of your custom dieline with artwork applied take 7-10 business days. Pre-production samples of the final print are available on rigid-box and large-volume briefs. Our creatives hold the box, fold it, photograph it — then artwork lock is easy.
Do you offer eco-friendly and sustainable packaging options?▾
Yes — FSC-certified kraft and corrugated board, 100% recycled pulp, soy-based inks, acid-free tissue, rPET void fill, honeycomb paper wrap and plastic-free tape are all available across the range. We'll route agencies with sustainability briefs toward lower-ink packaging and recycled substrates that carry the story credibly at the counter.
Can Sense2 kit, pack and dispatch our packaging with the product inside?▾
Yes — kitting, assembly, multi-site drops, home-address dispatch for distributed teams and timed-release dispatch for launch windows are all handled from our Sydney warehouse. One brief, one PM, one invoice. Agencies run entire campaign launches through us because the rhythm is reliable.
Related categories
Ready to build something people will actually keep?
Tell us the moment — the onboarding day, the brand refresh, the conference, the client thank-you — and we’ll shortlist, mock up and deliver. Samples available (cost + freight applies, credited back), 48-hour dispatch, creative thinking included.
Find it. Love it. Keep it.
More about Promotional Packaging▾
Custom Packaging & Branded Merchandise Boxes
Custom packaging turns every delivery into a branded touchpoint, transforming a plain box or mailer into a moment that builds loyalty and generates social shares. Does your current packaging do justice to the product inside, or does it get ripped open and forgotten? Looking for eco-friendly mailers that align with your sustainability commitments? Sense2 has designed branded packaging solutions for Australian organisations for over 30 years, from rigid gift boxes to compostable satchels, with MOQs from 25 units. Wrap Your Brand with Care and Creativity "The unboxing experience is the first chapter of your product's story. At Sense2, we craft custom packaging solutions—from eco-friendly mailers to luxury gift boxes—that transform every delivery into a memorable, branded moment of delight." Wrap your promo items in style with custom gift bags, boxes, and eco-friendly mailers. Thoughtful packaging transforms every delivery into a branded unboxing experience. At SENSE2, we understand that custom packaging is more than just a way to protect your products; it's an opportunity to wrap your brand with care and creativity and make a memorable first impression.Who Orders Custom Packaging in Australia?
In our Spend Index of thousands of branded orders, packaging and presentation products account for a growing share of total spend as more organisations recognise the unboxing experience as a brand-building moment rather than a logistics afterthought. E-commerce brands like The Iconic, Adore Beauty, and Who Gives A Crap invest heavily in branded mailers that photograph well for social media. Corporate gifting programmes at Telstra, Commonwealth Bank, and Westpac use custom rigid boxes with foam inserts to present premium merchandise to VIP clients and new employees. Luxury and fashion houses including Zimmermann and Camilla commission bespoke tissue-lined boxes for seasonal launches. Agencies managing campaigns for government bodies—the Australian Tax Office onboarding kits, NSW Health employee welcome packs—order branded packaging that reinforces professionalism from the first interaction. Conference organisers for events like SXSW Sydney and Vivid Sydney source custom tote bags and branded box sets for delegate packs, while wine producers in the Hunter Valley and McLaren Vale order printed shipper cartons that double as retail-ready displays. Real estate groups such as Ray White and McGrath use presentation boxes for settlement gifts, and subscription box companies across Australia rely on consistent, high-quality branded packaging to maintain subscriber retention month after month.How Sense2 Compares
Mass-market packaging suppliers may offer lower per-unit pricing on standard formats, but Sense2's advantage lies in consultative design support, bespoke structural options, and the ability to integrate packaging with a broader branded merchandise programme. For agencies coordinating multi-product gift sets, government buyers requiring Australian-made or FSC-certified materials, and heritage brands needing premium finishes like foil stamping and embossing, Sense2 provides a specialist packaging service that generic box suppliers cannot match.Why Custom Packaging is a Branding Essential
Your packaging is often the first tangible interaction a customer has with your brand. A well-designed box or bag sets the stage for a positive experience and tells your brand's story before the product is even revealed. "Custom packaging is a canvas for your branding. It's where your logo, colors, and messaging come together to tell your brand's story. Well-designed, sustainable packaging ensures your products arrive safely while creating an unboxing experience that customers will remember."Explore Our Range of Custom Packaging Solutions
Our collection is designed to offer the perfect packaging solution for any product, from retail merchandise to corporate gifts.- Custom Merchandise Boxes: Tailored to your product dimensions and branding aesthetics, our custom boxes add a touch of sophistication and protection to your merchandise.
- Branded Merchandise Bags: Perfect for retail and events, our custom merchandise bags are available in a range of materials and can be printed with your logo for a cohesive brand identity.
- Eco-Friendly Mailers & Packaging: Showcase your commitment to the environment with our sustainable options, including recycled and biodegradable mailers that appeal to eco-conscious consumers.
- Custom Merchandise Displays: Enhance your in-store presence with custom displays designed to showcase your products and attract customer engagement.


