Ordering a custom honeycomb mailer is a different process to buying a stock size off a shelf, and knowing the steps in advance means you are not caught out by a minimum order quantity, a longer lead time, or a size that only becomes obvious once a sample is in your hands. This page covers how getting a custom honeycomb mailer solution actually works, from first enquiry to delivery.
The steps in a custom honeycomb mailer order
- Describe your product and order profile. Product dimensions, weight, fragility, and roughly how many you ship a month. This is what a supplier needs to recommend a size and specification, not just take an order.
- Decide the specification. Size (see the size and spec guide), closure type (self-seal or tear-strip), whether you need reinforced construction, and whether a certified compostable claim matters to you.
- Branding decision. Plain kraft, or custom print, covered in full on custom-branded honeycomb mailers.
- Request a sample. A sample on your actual size and stock, with your artwork if printed, before committing to a production run.
- Confirm the minimum order quantity. Custom sizing and print both usually carry a minimum, ask for the real number rather than “contact us for a quote,” and expect it to be quoted to your actual volume rather than a figure built for a national retailer.
- Production and delivery. Custom runs take longer than stock reorders, plan the timing around a launch or a seasonal peak accordingly.
Stock vs custom: which do you actually need
| Stock honeycomb mailer | Custom honeycomb mailer | |
|---|---|---|
| Sizing | Standard size bands | Sized precisely to your product |
| Branding | Plain kraft | Printed to your design |
| Lead time | Fast, from stock | Longer, production run required |
| Minimum order | Low or none | Higher, to cover setup |
| Best for | Testing the format, low or variable volume | Established volume, brand-consistent unboxing |
A common path is starting on a stock size to prove the format works for your product, then moving to a custom specification once volume and branding needs justify it.
How Carewell Group helps
Carewell Group is an Australian packaging manufacturer and supplier. We take a specification-first approach: understanding your product and order profile before recommending a size, closure and material, then supplying a sample before any production run. See the honeycomb mailer overview for the full comparison against bubble wrap and poly mailers.
Carewell can meet all your packaging needs for your business. Talk to our expert and we will work to your required MOQ. Call +61 (02) 8760 1491 or request samples and a packaging review.
Frequently asked questions
How long does a custom honeycomb mailer order take?
Longer than a stock reorder, since it involves specification, sample approval and a production run. Plan ahead of a launch or seasonal peak rather than ordering at the last minute.
What is the minimum order for a custom honeycomb mailer?
It varies by size and whether printing is included, and should be quoted against your actual volume rather than a fixed figure built for a large retailer.
Should I start with a stock size or go custom straight away?
If you are still proving the format works for your product, start with a stock size. Move to a custom specification once your volume and branding needs justify the minimum order quantity.
Sources
- Australia Post, parcel size and packaging guidelines: auspost.com.au
Written by Alif Vasaya, digital and content strategy, Carewell Group. Carewell Group is an Australian packaging, food packaging, tape, industrial safety and 3PL supplier serving all of Australia. Last updated 17 September 2026.