This article contains a description of mailing tubes, how they are made, and their use.
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A mailing tube serves as a sturdy and resilient cardboard container, purposefully crafted for transporting elongated and thin items like rolled-up maps, banners, and posters. Its robust exterior provides essential protection and security for the contents, making it easy to handle and ship.
Mailing tubes come in a diversity of shapes, including cylindrical, triangular prism, and square prism forms. They are constructed from either durable paperboard or corrugated board. Cylindrical tubes are produced by wrapping Kraft and test paper around a mandrel, whereas triangular and square tubes are assembled like collapsible boxes. Regardless of their design, all mailing tubes are engineered to withstand the demands of mailing and shipping processes.
Mailing tubes utilize materials such as Kraft paper, test paper, and paperboard, which are adhered or folded into tube structures. Material choice depends on the necessary durability, as these tubes might need to safeguard valuable items or sensitive documents. Options for sealing mailing tubes include plastic or aluminum caps, folded cardboard, or tape, selected based on the type of items being shipped and the desired level of protection.
Packing and shipping materials have evolved significantly over time in response to advancements in logistics, packaging engineering, and modern shipping requirements. Historically, long or delicate items such as blueprints, artwork, posters, or industrial rods were placed in standard cardboard boxes or simply wrapped in paper. This provided minimal protection, often resulting in bent, creased, or otherwise damaged products during shipping and handling.
Modern mailing tubes—also referred to as cardboard tubes, shipping tubes, poster tubes, and document mailers—have been engineered for optimal protection and versatility during transport. Available in a range of diameters, thicknesses, shapes, and construction materials, today’s mailing tubes cater to diverse industries and custom packaging needs. Their crush-resistant structure, tear-proof design, and recyclable materials make them a preferred choice in e-commerce, artwork shipping, architectural blueprint protection, and more. Additionally, most mailing tubes are eco-friendly, as both fiberboard and corrugated cardboard options can be recycled or repurposed, reducing environmental impact and supporting green supply chain practices.
Telescoping mailing tubes, sometimes called adjustable tubes or expandable mailing tubes, feature a unique length-adjustable design—ideal for shipping various sizes of documents, maps, banners, engineering drawings, parts, and posters without excess empty space. Crafted from spiral-wound, heavy-duty cardboard, these robust tubes consist of a smaller inner tube that slides in and out of a larger exterior tube, providing a secure, custom fit for elongated or irregularly-sized items. Telescoping mailing tubes are especially popular in architectural and industrial applications, as well as the poster distribution sector.
With reliable crush resistance and high weight capacity, telescoping tubes excel in protecting long, heavy, or fragile shipments like metal rods, PVC pipes, or blueprints during courier transit. Their quick length adjustment eliminates the need for cutting tubes down to size. Once the internal and external tubes are adjusted, the connection point is typically secured with packaging tape or a shipping label. Many shippers choose telescoping tubes for the flexibility and cost savings they offer on variable-length orders.
Snap seal mailing tubes, also referred to as crimped end tubes or friction lock tubes, are designed for rapid, hassle-free packaging. Eliminating the need for end plugs or additional tape, snap seal tubes feature one pre-crimped end while the opposite end remains open for loading. After inserting the packaging contents—such as posters, rolled graphics, product samples, or photographs—the open end is manually crimped shut, forming a durable friction seal that remains secure during shipping. Despite being one of the most economical mailing tube options, they provide robust, rigid construction thanks to multiple layers of Kraft paper spirally wound around a mandrel.
Snap seal tubes are commonly chosen for mailing promotional materials, posters, blueprints, or lightweight industrial parts, and are available in a wide range of tube lengths and diameters. This makes them an excellent choice for mass mailings or fulfillment operations seeking both speed and reliable postal protection for long, narrow items. Snap seal mailing tubes also offer enhanced operational efficiency, reducing air gaps in packages and lowering overall shipping costs.
The manufacturing process for triangular mailing tubes—sometimes called triangle tubes or triangle shipping boxes—is similar to that used for corrugated cartons. These tubes are die cut with flaps for folding and gluing. The biggest advantage of triangular mailing tubes is their stability—they lay flat, stack efficiently, and do not roll during transport, storage, or warehouse handling, reducing load shifting and transportation risk.
Triangular mailing tubes are constructed from durable corrugated board and available in a broad array of lengths and adjustable side widths to suit custom mailings, product samples, shipping artwork, or architectural plans. These cardboard tubes can be custom printed with branding or handling instructions for added convenience. Triangular tubes feature multiple opening configurations: some use ends with overlapping flaps and tuck-in tabs for tamper resistance, while others resemble clamshell boxes or feature a lid for side-loading. This adaptability contributes to their popularity in both retail packaging and industrial shipping operations.
The ability to customize the dimensions, strength ratings, and opening styles allows designers to meet even the most unique product protection requirements. Whether shipping blueprints, textile samples, or rolled posters, triangular mailing tubes offer outstanding versatility, cost efficiency, and secure automated fulfillment integration.
Plastic plug mailing tubes are a versatile, tamper-evident packaging solution favored for retail, industrial, and laboratory shipping applications. These tubes utilize secure-fitting plastic plugs, rather than crimped or friction-locked ends, to create a tight, reusable seal. Manufactured with spiral-wound Kraft paper, fiberboard, or specialty paperboard, plastic plug tubes are highly resistant to crushing, moisture ingress, and contamination.
Variation in plug designs include permanent metal plugs, heavy-duty paper board end caps, permanent or removable plastic plugs, and locking mechanisms. Tube diameters range from a few inches for shipping samples to nearly ten inches for industrial components, and overall length can be fully customized. The snug-fitting plastic end plugs protect sensitive contents—such as product prototypes, engineering parts, laboratory samples, and high-value documents—from dust, dirt, water, and impact during transit. These attributes make plastic plug mailing tubes a leading choice for shipping delicate or valuable items that require superior protective performance.
Metal plug mailing tubes provide an even greater level of durability and permanence compared to plastic plug tubes. These tubes feature robust end closures typically used for high-value or industrial shipments that demand a tamper-proof, long-lasting seal. Metal plugs come in several designs, including wedge-fit, self-locking, and mallet-sealed configurations, often permanently affixed for maximum security.
Constructed for frequent reuse, metal end plug mailing tubes are manufactured in a wide range of diameters—from just over an inch to nearly nine inches—and built from thick, spiral-wound Kraft paper reinforced with metal fittings. The heavy-duty construction makes them an ideal solution for repeated shipments, long-term storage, and the transport of metal rods, machined parts, or sensitive blueprints. Their enhanced durability ensures reliability for demanding environments, while still enabling custom branding for professional presentation. In shipping and packaging applications requiring maximum product protection and reusability, metal plug mailing tubes are the trusted industry solution.
In the mailing tube packaging industry, plastic, metal, or other types of plugs (also known as enclosures) are tailored to meet diverse shipping requirements across manufacturing, e-commerce, and distribution networks.
Curled end mailing tubes, also known as rolled edge canisters or rolled rim tubes, are distinguished by their seamless, tamper-resistant end structure. They can be manufactured as single-piece tubes, two-piece adjustable tubes, or telescoping versions for variable-length shipments. In these designs, the circumference of one end (or both ends) is rolled or curled inward, and a disc of sturdy paperboard or cardboard is bonded over the curled edges, providing a strong protective seal.
Two-piece adjustable curled end mailing tubes feature one section capped with a rolled rim, while three-piece telescoping tubes combine a single-piece tube nested between two curled end tubes to create an adjustable length. This design is commonly used for art prints, posters, product samples, and specialty retail packaging due to its effective protection against crushing and easy opening for recipients. For branding, curled end tubes can easily be printed or labeled, adding a premium touch to direct-mail marketing campaigns or gift packaging.
Paper cap mailing tubes are classic mailing solutions featuring end caps made from pressed Kraft paper shaped into snug-fitting cups that cover the ends of the tube. Widely used in the shipping of posters, rolled artwork, and blueprints, the caps can be glued or stapled to one end of the tube, while the other cap is removable for easy loading and removal of contents. Paper cap tubes offer lightweight protection, are cost-effective, and can be produced in various colors or printed to align with branding or handling requirements. They provide a reliable choice for businesses prioritizing recyclable packaging and sustainable shipping solutions for lightweight products.
Square mailing tubes, sometimes referred to as box-style tubes or rectangular shipping tubes, are constructed in a similar fashion to folding cartons and die-cut boxes. These mailing tubes can be designed with one open end or a side-loading configuration, like a conventional shipping box. One of the primary advantages of square mailing tubes is their ability to prevent rolling and shifting during shipping and storage—ensuring more stable stacking in parcels and on warehouse shelves.
Manufactured from sturdy white coated or corrugated paperboard, square tubes offer excellent durability, structure, and crush resistance while remaining easy to assemble, fold, and seal. Because they ship flat, they reduce inbound storage requirements and lower shipping costs for bulk packaging buyers. Square mailing tubes are increasingly chosen by fulfillment centers, document management companies, and art galleries seeking both reliable product protection and efficient automated processing.
Kraft paper is an essential material in the paper packaging industry, primarily used in the production of corrugated cardboard and paperboard. Its superior weight, thickness, and tear resistance make Kraft paper ideal as the outer liner for cardboard boxes and mailing tubes. Corporate buyers and packaging engineers often select Kraft paper for its exceptional rigidity, durability, and ability to maintain structure under demanding conditions. Its eco-friendly qualities and recyclability also contribute to its widespread preference for sustainable packaging solutions and industrial applications.
The manufacturing of Kraft paper centers around a chemical pulping process that transforms wood fibers into a resilient pulp. Pulp is then processed and, if necessary, coated or laminated to enhance the paper’s strength, water resistance, and protective properties—key features valued in the shipping and packaging sectors.
Kraft paper production begins with converting raw wood chips into wood pulp. This crucial stage utilizes the Kraft process—also known as sulfate pulping—to achieve optimal fiber separation and paper strength. Wood chips are combined with hot water, sodium hydroxide, and sodium sulfide, then placed under high pressure inside large digesters. Each production cycle may handle 10 to 20 tons of material, making it effective for both commercial and industrial-scale output. The chemicals break down lignin, hemicellulose, and cellulose, with the primary goal of removing the lignin that binds fibers together but leads to weak, brittle paper if retained.
Lignin typically accounts for about 25% of a tree’s composition, with the remainder consisting of 50% water and 25% cellulose fiber—the target ingredient for premium Kraft paper. By extracting lignin and preserving cellulose, the process yields a strong, long-fiber pulp vital for heavy-duty cartons, high-performance mailing tubes, and multiwall Kraft bags.
The initial processing step involves removing bark and oversized wood chips unsuitable for pulping. Quality-controlled, sorted chips proceed to the digester, where chemical cooking dissolves the lignin and liberates cellulose fibers. This separation ensures that the resulting Kraft paper exhibits enhanced structural integrity, making it a trusted choice for packaging, industrial wraps, and carton manufacturing.
After pulping, further purification is necessary to eliminate residual lignin and non-cellulosic materials, especially when producing bleached Kraft grades for premium packaging or printing papers. The bleaching process treats pulp with bleach and water in multiple stages, incrementally removing discolorants and contaminants. As a result, the pulp becomes notably brighter and whiter, suitable for demanding applications such as custom-printed cardboard tubes, food-safe packaging, and high-value paperboard products.
Following the bleaching phase, the purified pulp is ideal for conversion into Kraft linerboard, specialty paper stocks, or reinforced Kraft paper used for heavy-duty packaging and shipping solutions.
To produce Kraft paper from pulp, manufacturers introduce performance-enhancing additives to reinforce tensile strength and surface durability. The pulp—most often strengthened by sulfate—spreads over a wire mesh or Fourdrinier machine, where water is drained, and cellulose fibers interlock to form a continuous paper web. Advanced machinery presses, dries, and smooths the paper through a calendaring system, optimizing surface finish and consistent thickness, crucial for automated box-making and efficient warehouse storage of packaging materials.
Roughly 84% of the water is removed during initial drying, with further steam heating ensuring complete fiber bonding and moisture removal. Once final drying is complete, Kraft paper is wound onto steel cylinders or jumbo rolls for subsequent slitting, sheeting, or conversion into paperboard, corrugated medium, or mailing tube stock. The process allows for customization of basis weight, thickness, and coating to meet precise shipping, warehousing, or product-protection needs.
Kraft paper comes in a range of grades and finishes designed for specific applications, including protective packaging, industrial wrapping, box making, and specialty uses. Only the strongest and most durable qualities are selected for manufacturing cardboard mailing tubes and heavy-duty packaging boards. High-quality Kraft variants contribute to superior crush resistance, improved stackability, and enhanced resilience during transit and storage, meeting the rigorous demands of global eCommerce, logistics, and supply chain operations.
Virgin natural Kraft paper is produced from 100% pure cellulose fibers, delivering unmatched tear strength, puncture resistance, and high bursting strength. Its manufactured integrity allows it to be layered for superior thickness and durability. This robust paper type is a staple in creating both single-wall and double-wall corrugated boxes, postal tubes, and heavy-duty carton liners. Its natural brown finish also aligns with sustainable packaging trends, catering to businesses and consumers seeking eco-friendly, recyclable shipping materials.
Recycled Kraft paper is manufactured using post-consumer and post-industrial fiber content. While it may offer slightly lower strength compared to virgin grades, it is ideal for inner ply layers, dunnage, and cost-effective product wraps. Its use helps reduce environmental impact and plays a vital role in closed-loop packaging systems, supporting corporate sustainability initiatives and green certification requirements.
Clay-coated Kraft paper features a smooth, printable surface enhanced by a clay-based top layer. This treatment allows for advanced finishing options—such as white, glazed, grease-resistant, and ribbed textures—making it well-suited for premium retail boxes, custom branding, and food packaging that requires clean aesthetics with barrier properties.
Laminated Kraft paper, distinguished by its added protective coating, delivers improved mechanical strength, dimensional stability, and superb stiffness for packaging that must withstand crushing or moisture exposure. Laminated stocks are frequently chosen for industrial packaging, bulk shipping, and specialty mailing tubes that require consistent performance and protection during handling and storage.
In addition to these, Kraft paper is also commonly fabricated into paper bags, frame backings, release liners, interleaving sheets for steel production, and specialty protective sheets. Its versatility in packaging solutions makes it a go-to material across diverse industries—from eCommerce fulfillment to heavy industrial logistics. The varieties mentioned above are particularly preferred for producing postal tubes, carton wraps, and structural packaging components.
Cardboard mailing tubes come in two main types, each produced through distinct processes. The manufacturing of cylindrical cardboard tubes involves a specific set of procedures that differ from those used for creating square and triangular tubes, which follow similar methods to box production.
Square and triangular mailing tubes are created from sheets of corrugated cardboard or paperboard, which are cut and shaped accordingly. In contrast, cylindrical cardboard tubes are constructed by gluing sheets of Kraft paper and wrapping them around a mandrel.
The initial stage in producing cylindrical mailing tubes involves cutting large rolls of Kraft paper into narrower strips. Multiple strips may be combined and fed onto a mandrel to form the sides of the tube. Typically, sturdy and durable Kraft paper is utilized to ensure the tube remains rigid and robust.
The wall thickness of the tube is determined by the number of layers of Kraft paper wound onto the mandrel as well as the thickness of the paper itself.
Prior to the paper ribbons being wrapped around and fed by the winder onto the mandrel, they pass through an adhesive bath, which is a cascading gluing system that pumps glue onto each ply or layer of paper. As the access glue accumulates, it is wiped off and sent back into the system.
The winder collects and wraps layers of paper around the mandrel, continuously pulling the paper ribbons to create a spirally wound tube. The coordination between the mandrel, winder, and adhesive is crucial to the tube formation process.
The paper ribbons are wrapped around the mandrel, which sets the inner diameter (ID) of the mailing tube. Before the glue-coated ribbons are wound around the mandrel, an unglued inner liner is applied to prevent the glued ribbons from sticking to the mandrel, allowing the tube to slide easily for the cutting process. The thickness of the cylindrical mailing tube is determined by the number of layers of paper ribbons wrapped around the mandrel, including the thickness of the Kraft paper used.
The winding of paper ribbons around the mandrel is a continuous operation. Once each tube is formed, it progresses along the mandrel to the cutting machine. The machine grabs and rotates the tube while a cutter trims it to the specified length. Manufacturers may use different cutting methods, such as knives, saws, or other tools. The cutting process is designed to be swift to prevent burrs or rough edges, with the length of the mailing tube being determined by the movement of the cutter.
In one cutting method, multiple knives are arranged in a row. The spacing between these knives and their number are adjusted to achieve the desired tube lengths, allowing for the simultaneous cutting of several tubes to enhance production efficiency.
The initial phase in producing triangular and square mailing tubes involves designing the shape using computer-aided design (CAD) software. This software generates a graphic representation of the box's desired shape and dimensions. The design can either be a standard template suitable for various products or customized to fit specific customer requirements. The resulting graphic is reviewed to create a digital file, which is then used to produce a die for cutting out the box.
Mailing tubes are constructed from either paperboard or corrugated board, with the choice of material influenced by the intended use and expected handling conditions. Corrugated board is generally recognized as the more robust and resilient option compared to paperboard.
Paperboard � Paperboard is a widely used material in the packaging industry, commonly found in milk cartons and various commercial product packaging. It is produced from Kraft paper and test paper, with test paper making up the inner layers and Kraft paper forming the outer layers. Paperboard is suitable for mailing tubes that face less rigorous conditions and require less protection.
Paperboard is best suited for mailing tubes that are not subjected to severe handling and for packaging items that require minimal protection. Despite its strength, paperboard lacks the impact resistance offered by corrugated board.
Corrugated Board � Corrugated board is built to endure heavy-duty use. It comes in various forms, each featuring an outer layer of Kraft paper, a middle layer of wavy fluting, and an inner layer of additional Kraft paper or test paper. This construction makes corrugated board ideal for supporting substantial weights. Mailing tubes made from corrugated board are used for shipping heavy tools, equipment, and other substantial items. Due to their robust impact resistance, corrugated mailing tubes are often reused and are effective for both shipping and storage.
A cutting die is utilized to shape boxes from flat sheets of paperboard or corrugated board. The die features cutting edges known as rules, which can be either sharp to cut through the cardboard or slightly dull to score the material for folds, flaps, and other creases.
Foam is used on the die to secure the cardboard in place, preventing it from shifting and avoiding damage. This foam also assists in guiding the rules accurately into the sheet, ensuring precise cuts.
For large-scale production of mailing tubes, multiple dies are arranged around a rotating cylinder. As extensive sheets of paperboard or corrugated board move through, the cylinder rotates and presses the dies against the sheets, rapidly producing numerous mailing tubes.
Dies are available in various sizes, shapes, and dimensions. Box manufacturers maintain a range of dies that can be affixed to cylinders for the efficient production of mailing tubes. This method ensures high precision and consistent quality in the finished products.
After being cut by the die, the boxes are stacked, bound, and readied for shipment. They are kept flat to simplify the shipping process. This method applies to both triangular and square mailing tubes. By palletizing these flat tubes, hundreds can be efficiently handled and transported.
Similar to pizza boxes, triangular and square mailing tubes are folded by the end user as needed. When flattened, these tubes are more compact, making them easier to store and quickly accessible when required.
Advancements in modern technology have led to the development of an array of inventive and sophisticated boxes for product display and shipment. Among these innovations are the diverse types of cardboard mailing tubes, reflecting the continuous evolution in the industry. Manufacturers are dedicated to enhancing the durability and strength of their products to cater to the needs of both delicate and specialized items.
Cardboard mailing tubes play a crucial role in safeguarding products. Designed to endure the demands of millions of shipments annually, these tubes are crafted from various types of cardboard to accommodate both fragile items and robust tools. Their construction ensures reliable protection throughout the shipping process.
In contrast to bulky boxes intended for multiple items, cardboard mailing tubes offer a compact and efficient solution. Their small size and streamlined design allow for easy packing of either multiple items or a single item. This compact nature makes mailing tubes ideal for optimizing space during both shipping and storage.
Cardboard mailing tubes are extensively utilized for safeguarding sensitive and delicate items. Their sturdy, rigid walls and securely sealed ends ensure that the contents remain intact during transit. The construction of these tubes minimizes movement inside, providing enhanced protection against damage and ensuring that items arrive in optimal condition.
For many years, cardboard mailing tubes have been the preferred choice for dispatching blueprints, maps, designs, and prototypes for review or official purposes. Their secure, tight seals make them highly reliable for transmitting important or confidential documents. The robust construction of these tubes prevents breakage, safeguarding the contents and maintaining their confidentiality and security throughout the shipping process.
Shipping documents with envelopes, folders, or bulky boxes can be quite costly and inefficient due to their size and expense. Many companies have discovered that using cardboard mailing tubes for sending documents, prototypes, and plans offers a more economical and practical solution. The streamlined design of mailing tubes reduces shipping costs and saves space, making them a more convenient choice.
During sorting and collection, envelopes and folders often blend in with other mail, making them easily overlooked and mixed with regular or junk mail. In contrast, cardboard mailing tubes have a distinct shape and appearance that makes them immediately recognizable. Their unique design ensures they stand out, emphasizing their significance and ensuring they are not missed.
Given the numerous advantages of cardboard mailing tubes, choosing the right one for your shipment is crucial. Manufacturers typically provide guidelines to help customers select the appropriate mailing tube based on their needs. By paying close attention to these recommendations during the design and selection phases, you can minimize mistakes and protect your items from damage.
The first step in selecting the right mailing tube is to accurately measure the dimensions of the item to be shipped. The tube must be sufficiently large to fit the item comfortably. It's essential to measure both the length and diameter of the item, keeping in mind that for non-circular items, an approximate diameter should be used to ensure a proper fit within the tube.
For items with unconventional shapes, triangular or square mailing tubes might be more suitable, as they can accommodate irregular forms without requiring special adjustments.
Choosing the right durability for a cardboard mailing tube depends on the weight and nature of the item being shipped. For lightweight items like maps, blueprints, and posters, a standard paperboard tube may suffice. However, for heavier items such as tools and instruments, opting for a corrugated board mailing tube is more appropriate due to its enhanced strength and durability.
When shipping fragile items, special considerations are necessary despite their lightweight nature. These items need extra protection to prevent damage during transit. While paperboard mailing tubes may not offer adequate protection, corrugated board tubes are designed to absorb and withstand impact. For added security, select mailing tubes with internal padding or multiple layers of corrugation to provide enhanced protection for delicate and fragile contents.
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