For an online brand, the package is the first thing a customer touches. A plain brown box says "delivery". A branded mailer says "you bought something special". Here's how to get there without blowing your packaging budget.
Mailer box or poly mailer?
Custom mailer boxes are self-locking boxes that fold together without tape. They protect products well, stack neatly and create a proper unboxing moment. They're best for:
- Cosmetics, candles and skincare
- Jewellery and accessories
- Subscription boxes and gift sets
- Anything fragile or premium
Poly mailers are lightweight, tear-resistant plastic bags. They cost less to buy and less to ship, and they're perfect for:
- Apparel and soft goods
- Anything that can't break
- High-volume, lower-priced orders
Many brands use both: mailer boxes for gift sets and premium products, and colored poly mailers for everyday clothing orders. If items need extra protection without a box, bubble mailers are the middle ground.
Get the size right
The right size saves money twice. You pay for less packaging, and you avoid paying to ship air. Before ordering:
- Measure your most common order, including any tissue or inserts.
- Add a little room so products slide in without force.
- Check carrier size and weight tiers. A slightly smaller box can drop you into a cheaper shipping band.
Our premium mailer boxes come in five sizes, from a small 7" box for jewellery up to 10.6" boxes for apparel and kits.
Where to print: outside or inside?
Outside printing turns every delivery into an ad on the doorstep. Inside printing creates a surprise when the lid opens. If your budget allows one, choose based on your goal:
- Want visibility and brand awareness? Print the outside.
- Want a "wow" moment people share online? A bold inside print gets photographed.
Build the unboxing in layers
You don't need everything at once. Add layers as you grow:
- Branded box or mailer: the foundation.
- Custom tissue paper: wrapping products in printed tissue is one of the cheapest ways to make an order feel giftable.
- Insert card: a thank-you note, care instructions or a discount code for the next order.
- Stickers: a branded sticker to seal the tissue, or a freebie for customers to keep.
Each layer costs cents per order but adds to the feeling that someone cared about this package.
Use the insert card to drive repeat orders
An insert card is the most underrated piece of e-commerce packaging. Use it to:
- Thank the customer by name or with a handwritten-style note
- Offer a discount code on their next order
- Ask for a review or a photo tag on social media
- Explain how to care for, use or refill the product
Keep it practical
- Design for your packing team. Boxes that fold fast and close securely save time on every order.
- Order your best-selling size first. You can add more sizes later.
- Think about storage. Mailers ship and store flat, so check how much space your order quantity needs.
The takeaway
Match the mailer to the product, size it tightly, and build your unboxing in simple layers. A branded box, tissue and a thank-you card make a small brand feel established from the very first order.
