Sending clothes and textiles: mailer box, envelope, or box?
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by Verpakkingdeals.nl
6 min reading time
Textiles are light, soft, and require different packaging than a fragile product. Here's how to choose between a letterbox box, bubble envelope, and regular box, and how to pack clothes compactly and dry.
A thick sweater fits in a 30 by 20 centimeter box. The same sweater can also fit in a letterbox package that is 28 millimeters high — if you fold it properly and press the air out. That difference costs you nothing in material, but saves a tariff step per shipment. Anyone who regularly sends clothes, whether via a webshop or simply because something has been sold, benefits most from a few simple choices beforehand.
Textiles behave differently from the rest of your assortment. It doesn't break, it can take a beating, and it's light. But it absorbs air, wrinkles, and is sensitive to moisture. The packaging question is therefore not "how do I protect this from damage", but "how do I get this to the recipient as small and as dry as possible".
First compress, then choose a box
The most common mistake is that people first grab a box and then stuff clothes into it. Do it the other way around. Fold the garment as flat as possible, do not roll it (rolling makes it higher, not lower) and press the air out. Only then measure.
A few practical rules of thumb:
A T-shirt or leggings almost always fit letterbox dimensions.
Jeans or a hoodie usually just barely fit or don't fit — actually measure instead of guessing.
A winter coat, boots, or a set of multiple garments goes in a box. Forcing it will only result in torn packaging.
Always fold along the seams and place the largest flat surface at the bottom. This keeps the fold neat and prevents the recipient from having to iron something that shouldn't have been wrinkled.
Letterbox package: the cheapest route, if the height is correct
Pay attention to the height of 28 millimeters: that is the size you fill, not the size you can exceed. As soon as the lid bulges, the shipment is no longer considered a letterbox package by most carriers. Always check the current maximum dimensions with your own carrier, as these may change.
Does it add up? With the A6 bundle, you pay about eighteen cents per box, with the A5+ bundle about twenty-four cents. This is negligible per shipment compared to the tariff difference between a letterbox package and a parcel.
Bubble envelope: light, flexible, and forgiving
Where a box has a fixed shape, an envelope gives way. For clothing that is just too thick for a snug box but doesn't warrant a box, a padded envelope is often the better choice. They weigh little and the inside protects against chafing.
For flat items that shouldn't wrinkle — a signed poster with a merchandise order, a certificate, a passport-photo-like document — a sturdy A4 Envelope 229 x 324 mm, 10 pieces (€4.00) is enough. If there's something fragile, like a brooch or a badge on a card, use a Bubble Cushion Envelope 200x275 mm, 5 pieces (€5.00).
Moisture: the problem you only see at the recipient's end
Cardboard and paper absorb water. A package that has been in a wet delivery van or on a sidewalk for an hour may still appear dry on the outside while the inside is damp. With a book, you notice that immediately; with a cotton sweater, the recipient only notices it when it smells like a cellar.
Therefore, always wrap textiles in something water-repellent before they go into the box. A sheet of Bubble Wrap Roll 500 mm x 500 m (€12.95) does the job perfectly and costs almost nothing per shipment. Those who prefer a smooth inner packaging can use a bag — but never put a bare garment in a cardboard box if the shipment is on its way for a day.
Another detail often forgotten: smell. Do not store textiles next to cleaning products, perfume testers, or new rubber items. Cotton absorbs odors, and those travel with it.
Taping and sealing
A letterbox package that opens during transit will lose its contents because there's no weight inside to keep it closed. So, tape it thoroughly, even if the box has an insert flap. A roll of KINZO Packing Tape 50 meters x 48 mm (€3.00) is enough to start; if you ship systematically, you'll opt for the more economical Tape Rolls 6 pieces 48x66 mm (€21.00). If you work at a fixed packing station, a Kinzo Tape Dispenser with 2 rolls (€9.95) will pay for itself in time within a week.
Do you send valuable branded clothing or second-hand items that could lead to discussion? Then a Security Seal Sticker VOID, 60 pieces (€9.95) is a cheap insurance. Such a seal leaves visible traces if someone removes it, which significantly shortens any discussion about "it was already open."
Write the size or order number with a Permanent Marker, 5 pieces in 3 colors (€4.95) on the side of the box, not on the top. The shipping label will go over it.
Think ahead about returns
Clothing has the highest return rate of all product categories, simply because sizes disappoint. That's not a problem, as long as your packaging survives the return journey. Choose packaging that your customer can reclose: a letterbox package with an insert flap can be used twice, a sealed envelope cannot. Include a small piece of tape if that's important to you — it costs you a few cents and saves your customer service an email.
Get started
Don't order one of everything, but choose two formats that cover ninety percent of your shipments and keep stock of them. For most clothing sellers, these are one letterbox package and one bubble envelope, plus tape and a roll of bubble wrap. All formats can be found in Letterbox Packaging and in the broader collection Packaging & Shipping. Envelopes are grouped in Envelopes, tape and dispensers can be found in Tape. If you are unsure which format suits your items, or if you want a price for a larger purchase? Email info@verpakkingdeals.nl and tell us what you send on average — we'll calculate with you.
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