What Kind of Packaging is Best for Mailing Clothing?

You need to ship your clothing, but flimsy poly mailers¹ feel cheap. Bad packaging can wrinkle your product and ruin the unboxing experience², which hurts your brand's reputation.

The best packaging for mailing clothing combines protection with branding. This is usually a custom-branded corrugated mailer box³x](https://wansapackaging.com/what-kind-of-packaging-is-best-for-mailing-clothing/)%%%FOOTNOTE_REF_4%%%. For a premium feel⁵, use a rigid gift box⁶ placed inside a mailer for shipping.

I remember a fashion startup that came to us. They were shipping expensive silk shirts in simple poly bags. They got so many complaints about wrinkles and the cheap "feel" of their delivery. Upgrading their packaging wasn't just about getting a box; it was about protecting their high-quality product and elevating their customer's entire brand experience. This simple change made their customers feel like they were receiving a gift, not just an order. Let's break down the best options to achieve that feeling.

---

What is the best packaging for sending clothes?

You want your clothing to arrive perfectly. A cheap bag can get torn in transit, while a box that's too big adds unnecessary shipping costs⁷. Choosing the wrong option is both risky and expensive.

The best packaging depends on your product and brand goals. For durability and a great unboxing experience², a custom-sized corrugated mailer box⁴ is the top choice. For luxury items, consider a rigid box inside a mailer.

When a designer like Jacky is choosing packaging, he has to balance three things: protection, brand experience, and cost. A simple poly mailer is cheap, but it offers almost no protection from being crushed and provides a very forgettable unboxing experience². A box is almost always the better choice for a clothing brand that cares about its image. The "unboxing moment" is your first physical interaction with your customer. A beautifully designed box feels like a gift and is something customers often share on social media. That's free marketing you can't get from a plastic bag.

Packaging Options for Clothing

Option	Protection	Branding	Unboxing Experience	Cost
Poly Mailer	Low	Low	Poor	Very Low
Padded Mailer	Low-Medium	Low	Poor	Low
Corrugated Mailer Box	High	High	Excellent	Medium
Rigid Box + Mailer	Very High	Very High	Premium	High

For most e-commerce brands, the corrugated mailer box⁴ hits the sweet spot. It's strong enough to survive shipping, offers a large canvas for beautiful branding, and creates that exciting unboxing experience² customers love.

---

What packaging do you use to ship clothes?

You need a specific packaging solution, not just a general idea. You see other brands using nice boxes but don't know what they're called or what materials are used to make them.

We typically recommend a two-part solution for premium clothing. This includes a rigid drawer-style box⁸ for the clothing itself, which is then placed inside a protective corrugated mailer box⁴ for shipping.

4 sitting next to it." title="Two-Part Clothing Packaging System" />

This combination gives you the best of both worlds: a premium feel⁵ and total protection. For a T-shirt box, we usually use a sliding drawer box paired with an outer corrugated mailer box⁴ for the customer. The system works perfectly. The inner box provides the luxury unboxing, and the outer box takes all the hits during shipping.

The Inner "Gift" Box

This is the rigid drawer box, sometimes called a slider box. Its job is to present the product beautifully. It's not designed for shipping on its own. The drawer box material is a combination of rigid greyboard and specialty paper. It's essential that the drawer box uses rigid greyboard to ensure it protects the product!. Greyboard is a very thick, dense, and strong paperboard that doesn't bend. We wrap this structural greyboard in a custom-printed specialty paper that gives the box its color, texture, and branding.

The Outer "Shipper" Box

This is the corrugated mailer. Its only job is to get from our factory to your customer safely. It's built for durability to protect the beautiful gift box inside. This way, the customer receives a pristine inner box, free from scuffs, dirt, or shipping label⁹s.

---

How do you package clothing to mail?

Just putting clothes in a box is not enough. The items can shift around, get wrinkled, or just look messy. You need a consistent process to ensure every package looks professional.

To package clothing, first fold it neatly. For a premium touch, wrap it in branded tissue paper¹⁰. Place it snugly inside the primary box. Add any marketing inserts¹¹, and then seal it inside the outer mailer for shipping.

10 before placing it in a box." title="How to Pack Clothing for Mailing" />

A great package is the result of a great process. Following a few simple steps can make a huge difference in how your customer perceives your brand.

Step 1: The Fold

Always start with a clean, flat fold. Many brands use a small plastic folding board to make sure every single T-shirt or sweater is folded to the exact same dimensions. This consistency looks incredibly professional and minimizes wrinkles. The folded garment should fit neatly into your custom box.

Step 2: The Wrap

Wrapping the folded item in tissue paper is a simple touch that dramatically elevates the unboxing experience². It adds a layer of anticipation and makes the product feel more like a valuable gift. Using tissue paper printed with your logo or brand pattern is an excellent and affordable way to reinforce your brand identity.

Step 3: The Extras

Once the wrapped item is in the box, you have another marketing opportunity. This is the perfect place to include a small "thank you" card, a business card, or a flyer promoting another product. It’s a very personal way to connect with your customer.

Step 4: The Seal

Finally, place the inner gift box into the outer corrugated mailer. Seal the mailer securely with strong packing tape. Make sure your shipping label⁹ is applied flat and is easy to read.

---

What is the best way to mail clothes?

You have packed your item perfectly, but now you face the shipping counter. High costs and the risk of damage are major concerns. You need a strategy that is both safe and cost-effective.

The best way to mail clothes is to use a durable, lightweight, custom-sized box. This minimizes shipping costs⁷ by reducing dimensional weight¹² while still providing excellent protection.

9s, ready to be sent." title="Cost-Effective Clothing Mailers" />

Shipping costs can eat into your profits if you're not careful. The biggest mistake brands make is using a standard, off-the-shelf box that is too big for their product. All major shipping carriers like UPS, FedEx, and DHL use a pricing method called "Dimensional Weight," or DIM weight. They calculate a billable weight based on the package's size. If your box is large but light, you pay for the size, not the weight.

This is why a custom-sized box is so important. By creating a box that fits your folded garment perfectly, you eliminate wasted space. This directly reduces the dimensional weight¹² and therefore lowers your shipping cost on every single package. We design mailer boxes to be as compact as possible. We use materials like E-flute corrugated board¹³, which is very strong and rigid but also very thin and lightweight. This offers the best balance: it protects your product without adding unnecessary size or weight to the package. The best mailing strategy is to make your box as small and light as you can without sacrificing protection.

Conclusion

The best packaging for clothes protects your product, elevates your brand, and is cost-effective to ship. A custom two-part box solution is the perfect way to achieve all three goals.

---