Manufacturer-direct • 60 years US-made

Sustainable mailers, made direct.

Flat, jumbo, and expansion mailers in 100% recycled fiber. Custom-printed with your logo, made to any size, and priced in the open. Order one carton or scale to a pallet, straight from our US factory.

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Free samples • Ships nationwide • One-carton minimum
16 sizes Custom-printed Made-to-size Priced in the open
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FLAT • JUMBO • EXPANSION
FROM $0.30 / UNIT
60+ years US-made

60+ years US-made

Made in-house, no imports

100% recycled

100% recycled

Curbside recyclable

Prices posted

Prices posted

Buy online, no quote

Free samples

Free samples

Try before you buy

The full range

Everything we make, in one place.

Three mailer builds across sixteen sizes, every one recyclable, custom-printable, and available made-to-size. From a single carton on your desk to pallet volume on your dock.

Stock sizes · ready to ship
01 / FLAT

Flat Mailers

Rigid, slim mailers for apparel, prints, documents, and lightweight goods.

9 sizes • 250 / carton
from $0.30 /unit
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02 / EXPANSION

Expansion Mailers

Gusseted mailers that hold depth for boxed, bulky, and thicker goods without a box.

5 sizes • 200 / carton
from $0.59 /unit
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03 / JUMBO

Jumbo Mailers

Oversized rigid mailers for bulky apparel, textiles, posters, and multi-item orders.

2 sizes • up to 19×24 in
from $0.83 /unit
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Made to order · your brand, your size
Custom printing

Your logo on the mailer

Single or two color, brand matched, printed straight off our line with low minimums.

Request a quote
Custom sizes

Built to your dimensions

Need a size we do not stock? We make mailers to spec, no importer, no long lead times.

Talk to the factory
TerraPrint

Ready-made designs

Pre-designed printed mailers with no art fees, for a branded look without a custom setup.

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Why buy direct

You are buying from the line, not a reseller.

TerraBoard is a Papercone company, making mailers in Louisville for over 60 years. Most sustainable packaging reaches you through a distributor who marks it up. Buy from us and there is no one in between.

01

No middleman markup

Factory pricing, posted in the open on every size.
02

No inventory delays

We make it, so stock and lead times stay in our control.
03

True customization

Custom sizes and logo printing, straight off our line.
04

Low minimums

Start at one carton, scale to pallet volume when ready.
LOUISVILLE, KY • EST. 60+ YRS
Custom printing

Turn the box into the brand moment.

A plain mailer ships a product. A printed one earns a photo. We print your logo direct from our presses in single or two color, brand-matched, with low minimums and no importer in the middle.

Request a Custom Quote See How It Works
Prefer a ready-made design, no art fees? Explore TerraPrint →
TerraPrint • ready-made printed mailers

Branded mailers, no art fees.

Not ready for a full custom run? TerraPrint is our line of pre-designed printed mailers. Choose a look, ship it branded, and skip the setup cost. The same 100% recycled build, ready to go.

Curated designs No setup cost 100% recycled Ships fast
Explore TerraPrint Order a Sample

Sustainability & compliance

Recycled in. Recyclable out.

Every TerraBoard mailer is 100% recycled kraft fiber and curbside recyclable, with no plastic, foil, or synthetic coatings. Sustainable packaging that helps your brand meet its commitments and stay ahead of packaging rules.

  • 100% recycled content, not virgin plastic
  • Plastic-free and curbside recyclable
  • Supports packaging mandates and ESG goals
  • US-made, lower-mile footprint

Who we serve

Built for brands that ship.

From growing e-commerce shops to established distributors and high-volume
operations, TerraBoard scales from a single carton to pallet volume.

E-commerce brands

Apparel, textiles, jewelry, and soft-goods sellers who want branded, sustainable packaging without the middleman.

Shop · custom print

Distributors & resellers

Volume buyers who want manufacturer-direct pricing and reliable US supply, with a fast path to a bulk quote.

Wholesale · bulk quote

High-volume shippers

Operations shipping at scale that need consistent quality, custom sizing, and dependable lead times.

Custom size · volume

Bulk & wholesale

Buy at volume, direct from the factory.

Tell us your sizes, volume, and print, and we build a quote around your order. Open a wholesale account for repeat ordering, dedicated terms, and a direct line to the people who make it.

Open a Wholesale Account Request a Bulk Quote

Pricing built to your order

Share your volume and we quote it, sized to what you actually buy.

Dedicated account & terms

Repeat ordering, saved sizes, and terms that fit how you buy.

Consistent US supply

We manufacture it, so stock and lead times stay dependable.

Custom at scale

Custom sizes and private printing on large runs, straight off our line.

Real support

Talk to the people who make it.

You are not routing through a reseller's call center. Our US-based team knows the product because we manufacture it, and we are here to help you get the size, print, and order right.

Contact Us Request a Quote

Help choosing a size

Not sure which mailer fits your product? We will point you to the right one.

Fast custom & bulk quotes

A real quote from a real person, not a form that disappears.

Wholesale onboarding

We set up your account and terms so repeat ordering is simple.

Before you commit

See it and hold it first.

Order a free sample kit and check the fit, material, and print on your own products. No cost, no commitment, and the fastest way to know it is right before you buy a carton.

Order a Free Sample