Custom Packaging Designed For Apparel Industry

Custom Apparel Boxes & Apparel Packaging

Clothing is one of the most returned product categories out there, and a surprising amount of that comes down to how the item arrives. Creased, damp, or squashed into a poly bag that split somewhere in transit. We have been printing custom apparel packaging at ZEE Packaging long enough to see what fixes that and what doesnt.

Start With The Garment, Not The Box

People usually come to us asking for a apparel box in a size they saw somewhere. That rarely works out. A folded tshirt and a folded hoodie need very different depths, and the wrong depth means either crushing or shifting.

Our common apparel box dimensions:

• 10" x 8" x 2" for tshirts and tank tops
• 12" x 9" x 2" for shirts, blouses and knitwear
• 14" x 10" x 3" for hoodies and sweatshirts, a deeper apparel box
• 16" x 12" x 4" for jackets, coats and outerwear
• 8" x 6" x 2" for kidswear and folded shorts
• 6" x 4" x 1" for socks, ties, belts and small accessories

Fold your garment the way you actually pack it, measure it, send us the numbers. Or mail a sample and we size the apparel packaging here.

Which Style Suits Your Brand

• Mailer box our best selling apparel box for ecommerce, ships flat, folds in seconds
• Folding carton light retail apparel packaging for tshirts, underwear and hosiery
• Rigid box the luxury apparel box, right for suits, gowns and bridal
• Shirt box with lid and base old school and still the cleanest apparel packaging for dress shirts
• Drawer or slide box nice for capsule collections and seasonal drops
• Corrugated shipper plain outer if your branded apparel box goes inside another carton

Board Talk

• Kraft corrugated, the workhorse for shipping apparel boxes, tough and cheap
• White corrugated when you want print on a shipping apparel box
• SBS C1S and C2S for smooth retail apparel packaging with heavy ink coverage
• Rigid greyboard 36pt or 48pt for premium apparel boxes
• Cardstock 14pt to 24pt for lighter cartons

One thing we tell clients a lot, dont go too thin on a mailer. A 3mm E flute apparel box holds shape far better than a thin cardstock one once a courier stacks things on it.

Making It Feel Like A Brand, Not A Parcel

The unboxing moment is basically free marketing, and good apparel packaging uses it.

Print the inside of the apparel box, a pattern or a note on the inner wall costs little and gets photographed a lot

• Soft touch lamination on retail apparel boxes
• Foil stamp the logo, gold, silver, rose gold, holographic
• Emboss or deboss on kraft, subtle and cheap
• Spot UV over matte for contrast
• Window patching if you want the garment visible

The Bits That Go Inside

• Apparel packaging is not just the outer shell:
• Tissue paper, plain or printed
• Belly band and sticker seal for your apparel box
• Thank you card, size guide, care instruction inserts
• Dividers when two pieces share one apparel box
• Return label sleeve, handy for clothing brands

Greener Apparel Packaging

• Recycled kraft apparel boxes with no lamination
• FSC certified board, certificate available
• Soy based ink
• Paper tape and paper void fill instead of plastic
• Right sized apparel packaging so you ship less air and pay less freight

Ordering With Us

• 100 unit minimum on every apparel box design
• Free 3D mockup and flat proof
• Free dieline and design help
• 5 to 8 business days urgent turnaround
• Free shipping worldwide

Brands stay with us because we keep the whole thing simple. Low minimum, quick turnaround, real people answering, and one team handling your apparel box from artwork through to delivery.

Frequently Asked Questions

Mailer or folding carton for online orders?
Mailer, almost every time. It survives courier handling and the crash lock bottom means your packer doesnt need tape.

Can you print inside the apparel box?
Yes and we recommend it. Inside print is one of the cheapest ways to make an unboxing feel considered.

Do you supply tissue and stickers as well?
We do. Plenty of clients order boxes, tissue and seals together so everything matches in one go.

Is kraft strong enough for a heavy jacket?
Plain kraft cardstock, no. Corrugated kraft, yes. For outerwear we always push toward corrugated.

Can we test a design before bulk?
That is exactly what our 100 unit minimum is for. Run a small batch, see how it performs, then scale.

What does an apparel packaging box cost?
An estimate is $0.40 to $1.10 per unit for folding cartons, $0.95 to $4.40 for mailer boxes and $2.20 to $8.50 for rigid boxes at moderate quantities. Shipping included. This is estimate only, so get a quote from our team for a exact figure.

How do we stop garments sliding inside?
Right sizing solves most of it. Tissue and a belly band handle the rest without adding much cost.