XCPaperboxCustom Packaging

Apparel Packaging

Mailers, boxes and shopping bags for fashion brands.

Apparel packaging has to feel premium in a fitting room and survive the post. We build poly-mailer alternatives, branded corrugated mailers, rigid apparel boxes, and boutique shopping bags. Apparel buyers — from DTC startup brands to established multi-SKU labels — face three recurring pain points: plastic poly-mailers that feel cheap at a moment when every unboxing is photographed, corrugated mailers whose seams tear on the last mile, and paper shopping bags whose handles fail under the weight of heavier outerwear. Typical order runs are 500–3,000 units for DTC startup brands and 20,000–100,000 units for established labels shipping to retail accounts. MOQ is 500 units for corrugated mailers and 1,000 units for rigid boxes and shopping bags. Lead time is 15–25 working days from sample approval; rush production is available for a 30% premium. Common questions from buyers include whether mailers can be custom-sized to reduce dimensional-weight charges, whether inside-print campaigns are cost-effective, and if we can match Pantone colors across mailer, box and bag. We address these by producing every mailer to your exact product dimensions (saving up to 30% on shipping costs), offering full-color inside prints at a small upcharge, and color-managing the entire order through a single press profile. Whether your unboxing lives on a landing page, a TikTok feed or a boutique counter, we engineer apparel packaging that looks premium on camera and holds up in courier trucks.

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Recommended products

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Material options

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Finish options

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Case studies

Recommended packaging

The formats that work best.

Materials

Recommended papers and boards

  • Corrugated E and B flute
  • Recycled kraft
  • Art paper

Finishes

How to finish it

  • Matte lamination
  • Foil stamping
  • Spot UV

Packaging trends

What we're seeing in apparel packaging.

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Paper-only mailers

Replacing plastic poly-mailers with corrugated and kraft paper alternatives — recyclable in any paper stream.

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Rigid shirt boxes

Magnetic-close rigid boxes for premium shirts, ties and accessories.

Case studies

Real apparel packaging projects.

Frequently asked

Questions about apparel packaging.

Yes — corrugated and kraft.

Our corrugated mailers and kraft bags are 100% plastic-free. We do not offer traditional poly-mailers as part of our catalog.

Yes — custom die-cut mailers from 500 units.

Every mailer is engineered to your product dimensions. Sizing a mailer to fit without void material reduces dimensional-weight charges by 20–30% and saves on filler cost. Standard turnaround for a custom die-cut mailer is 15 working days.

Yes — full-color inside prints.

Mailers are available with full-color outside-only, inside-only, or double-sided print. A double-sided mailer costs 12–18% more than an outside-only print and lets you run thank-you copy, social calls-to-action, or care instructions without a separate insert card.

Inquiry

Tell us about your apparel packaging project.

We'll get back to you within 24 hours with a tailored quote, lead time estimate, and material recommendations specific to the apparel packaging category.

Ready when you are

Send us a sketch, a reference, or a sample. We'll send back a quote within 24 hours.