What Kind of Packaging is Best for Mailing Clothing?

Shipping clothes seems simple, but wrong packaging leads to damaged goods and unhappy customers. Are your shipping choices hurting your apparel brand's reputation and bottom line?

For durable items like t-shirts or jeans, lightweight poly mailers are often best for cost-effectiveness. For delicate fabrics, structured items, or a premium unboxing experience, corrugated boxes offer superior protection and branding opportunities. The best choice balances protection, cost, and brand presentation.

Choosing isn't always obvious. Factors like the type of clothing, your brand image, and shipping costs all play a role. Let's explore the common options to help you decide what works best for your business.

Are Poly Mailers the Go-To Choice for Apparel?

Worried about high shipping costs eating into your profits? Heavy packaging adds unnecessary expense. Lightweight poly mailers offer a cost-effective way to ship many types of clothing safely.

Yes, poly mailers are frequently the go-to choice, especially for e-commerce brands¹. They are lightweight, water-resistant, relatively durable, take up little storage space, and are generally the cheapest option for shipping non-fragile clothing items.

As a manufacturer providing custom packaging solutions, we at Finer-Packaging see a huge demand for poly mailers from apparel brands shipping to North America and Europe. Their popularity comes down to several key advantages, particularly for businesses mindful of shipping weight and overall costs.

Advantages of Poly Mailers

• Cost-Effective: Both the unit cost of the mailer itself and the shipping cost are generally lower compared to boxes. Since carriers often charge by weight and dimensional weight, the light, flat nature of poly mailers offers significant savings.
• Weight Savings: Plastic film is much lighter than corrugated cardboard. This directly translates to lower postage costs, especially for items shipped individually.
• Water Resistance: Made from polyethylene film, these mailers protect clothing from rain, snow, and moisture during transit – something cardboard boxes don't inherently offer without special coatings.
• Space Efficiency: Empty poly mailers take up very little storage space compared to stacks of boxes. This is a big plus for businesses with limited warehouse or fulfillment space.
• Packing Speed: Sliding a folded garment into a mailer and sealing the self-adhesive strip is usually faster than assembling, filling, and taping a box.

Disadvantages of Poly Mailers

However, poly mailers aren't perfect for every situation:

• Limited Protection: They offer minimal protection against crushing, bending, or sharp impacts. This makes them unsuitable for very delicate items, structured garments (like hats), or items prone to wrinkling.
• Less Premium Feel: A standard poly mailer doesn't offer the same perceived value or unboxing experience as a sturdy, well-designed box.
• Environmental Concerns: Standard poly mailers are plastic. While recyclable options² (often using recycled content or being recyclable themselves #2 or #4 LDPE) exist, they still contribute to plastic waste concerns if not disposed of properly. We work with clients looking for more sustainable film options.

Types of Poly Mailers

Not all poly mailers are created equal. Common variations include:

• Standard Poly Mailers: Simple opaque or clear bags with a self-seal strip. Most common type.
• Bubble-Lined Poly Mailers: Include an inner layer of bubble wrap for added cushioning. Better for items needing a bit more protection, but thicker and slightly heavier.
• Expansion Gusset Mailers: Have expandable sides or bottoms, allowing them to accommodate bulkier items like hoodies or jackets more easily than a flat mailer.
• Returnable Mailers: Feature a second adhesive strip, making it easy for customers to reuse the mailer for returns.

At Finer-Packaging, we produce custom poly mailers (minimum order quantity typically applies, often higher than paper boxes, please inquire), allowing brands to print their logos and designs directly onto the bag, improving brand recognition even with this cost-effective option. We focus on durable film thicknesses suitable for international shipping.

When Should I Use a Box Instead of a Mailer?

Are delicate sweaters arriving wrinkled? Does your high-end clothing feel underwhelming packed in a plastic bag? Sometimes, a mailer just doesn't cut it for protection or presentation.

Use a box when shipping delicate fabrics³ (silk, cashmere), structured items (hats, shoes, blazers), multiple items together, gift orders, or when aiming for a premium, branded unboxing experience. Boxes offer significantly better protection against crushing and allow for more elaborate presentation.

While poly mailers win on pure cost efficiency for durable goods, boxes play a vital role in apparel shipping, especially for brands focused on product integrity and customer experience. We manufacture many custom corrugated boxes specifically for clothing brands targeting mid-range to high-end markets.

Why Choose Boxes for Clothing?

• Superior Protection: This is the primary advantage. Boxes provide rigid structure that protects contents from being crushed, bent, or excessively wrinkled during the rough and tumble of shipping. Essential for delicate materials, items with structure (like a tailored jacket or shoes), or easily damaged embellishments (beading, sequins).
• Enhanced Brand Experience: A custom-printed box offers a much larger canvas for branding than a mailer. It creates a more substantial, premium feel upon arrival. The unboxing experience can be significantly elevated with internal printing, custom tissue paper, and inserts – turning a simple delivery into a memorable brand moment.
• Shipping Multiple Items: Packing several clothing items neatly folded or arranged is often easier and more secure in a box than trying to stuff them into a mailer. Boxes prevent items from shifting excessively.
• Gift Presentation: If the clothing is being sent as a gift, a box feels more appropriate and special than a plastic bag.
• Stackability: Filled boxes stack much more efficiently and safely in warehouses and delivery vehicles compared to mailers.

Downsides of Using Boxes

• Higher Cost: Boxes cost more per unit due to the amount and type of material (corrugated board vs. plastic film).
• Increased Shipping Weight/Dim Weight: Boxes are heavier and take up more space (dimensional weight), leading to higher shipping costs compared to mailing the same item in a poly mailer.
• Storage Space: Empty boxes require significantly more storage space than flat mailers.
• Assembly Time: Boxes usually need to be assembled (folded into shape) and taped shut, adding time to the packing process compared to self-sealing mailers.

Common Box Types for Apparel

• Corrugated Mailer Boxes: The most common type for shipping clothes. Usually made from E-flute or B-flute corrugated board – offering a good balance of strength, printability, and relatively low profile. Often feature locking tabs or self-sealing strips. Finer-Packaging specializes in custom sizes and printing for these.
• Rigid Boxes: For ultra-premium or luxury apparel. Made from thick chipboard wrapped in paper. Offer the highest quality feel and protection but are significantly more expensive and heavier. More common for gift sets or very high-value items.

I recall working with a subscription box client who switched from mailers to custom printed corrugated boxes. They reported higher customer satisfaction and better brand perception, despite the increased packaging cost, as the unboxing felt more substantial. Ultimately, the decision to use a box hinges on balancing the need for protection and presentation against the higher costs involved.

How Can Customization Elevate My Apparel Packaging?

Is your plain mailer or standard brown box failing to make an impression? Competitors are using packaging to wow customers. Customization turns a necessary shipping container into a powerful branding tool.

Customization elevates apparel packaging through custom printing (logos, colors, patterns), unique structural designs⁴ or sizes for a perfect fit, and added internal elements like branded tissue paper, stickers, or thank-you cards, creating a memorable unboxing experience.

In today's competitive e-commerce landscape, packaging is often the first physical touchpoint⁵ a customer has with your brand. Making it count is essential. As a custom packaging manufacturer, Finer-Packaging helps apparel brands transform standard mailers and boxes into unique brand ambassadors. Our MOQ starts around 500-1000 pieces, making custom solutions accessible.

Branding Through Print

This is the most common form of customization. Instead of a blank surface, use it to reinforce your brand identity:

• Logo Placement: Prominently display your logo.
• Brand Colors: Use your specific brand colors (we can match Pantone PMS colors⁶ for spot printing or use CMYK for full-color designs).
• Patterns & Graphics: Incorporate brand patterns, taglines, or relevant graphics that reflect your clothing style (e.g., playful, sophisticated, eco-conscious).
• Inside Printing: Printing a pattern or message on the inside of a box creates a surprise element during unboxing.
• Finishes: On boxes, finishes like matte or gloss lamination, spot UV, or foil stamping can add a tactile and visual premium touch.

Structural Customization Benefits

While less common for standard poly mailers (though custom sizes are possible), boxes offer more structural options:

• Custom Sizing: Creating a box that perfectly fits your typical order size minimizes wasted space, potentially reduces dimensional weight shipping costs, and presents the clothing more neatly.
• Inserts: Custom inserts made from cardboard can hold items securely in place within a box, ideal for gift sets or delicate items.
• Unique Closures: While standard tabs or tape are common, unique locking mechanisms or magnetic closures (more for rigid boxes) can enhance the experience.

Creating an Unboxing Experience

Customization extends beyond the outer container. Think about the layers inside:

• Custom Tissue Paper: Printed with your logo or a subtle pattern, wrapping the clothing adds a layer of care and sophistication.
• Branded Stickers: Used to seal tissue paper or as an added decorative element.
• Thank You Cards/Inserts: A printed card with a thank you message, styling tips, or a discount code adds a personal touch.
• Cohesive Look: Ensure all elements – box/mailer, tissue, stickers, cards – use consistent branding⁷ for maximum impact.

We worked with a startup fashion label to design their first custom mailer box. By using a simple one-color print on kraft board and adding branded tissue paper inside, they achieved a stylish, eco-conscious look on a budget, significantly improving their customer feedback on packaging. Investing in customization, even simple elements, can significantly elevate your brand perception and customer loyalty. We offer both Digital Samples (for structure/layout checks) and Pre-production Samples (for final quality/color approval) to ensure your custom design is perfect before the main run.

Conclusion

Choose poly mailers for cost-effective shipping of durable clothes. Opt for boxes when protection, structure, or a premium unboxing experience is key. Customization enhances either option, turning packaging into marketing.