Custom Shirt Boxes & Shirt Packaging
A shirt arrives folded, and it has to stay folded. That sounds obvious but it is where most shirt packaging falls down. Too much depth and the fold collapses, too little and the collar gets squashed. We have printed enough of these at ZEE Packaging to know the difference a couple of millimeters makes.
Fold Depth Is The Whole Game
At ZEE Packaging, we size custom shirt boxes around the actual folded shirt, taking its length, width, stacked depth, collar support and tissue into account for a cleaner fit and presentation.
- Fold the shirt the way your packer actually does it
- Measure length, width and stacked depth
- Tell us if a collar support or tissue goes in
- Send a sample if you would rather we do the measuring
Get this bit right and the rest of the shirt packaging works itself out.
Styles We Build
ZEE Packaging offers custom shirt boxes in mutiple box styles to suit retail, ecommerce, gifting and premium shirt packaging needs.
- Lid and base shirt box the classic two piece, still the cleanest retail shirt packaging
- Folding carton with tuck ends lighter and cheaper, good for volume
- Mailer box crash lock bottom, our most ordered ecommerce shirt box
- Rigid box heavy board with a wrap, for formal and bespoke shirt packaging
- Drawer style slide out tray, feels like a gift
- Window shirt box die cut opening so the fabric and pattern show through
Sizes That Come Up Most
From slim dress shirts to heavier flannels, ZEE Packaging can tailor the box dimensions to the garment so the shirt sits neatly without excess space or compression.
- 12" x 8" x 1.5" for slim folded dress shirt
- 13" x 9" x 2" for standard shirt packaging, our most common size
- 14" x 10" x 2.5" for oxford and heavier weave
- 15" x 11" x 3" for two shirts in one box
- 16" x 12" x 3" for flannel and overshirt
Board We Recommend
At ZEE Packaging, you can match the board grade to your shirt box intended use. Use from our mutiple board options to maintain shape and presentation during handling and stacking.
- SBS C1S for a printed retail shirt box with heavy ink coverage
- Kraft board for a natural, understated look
- Corrugated E flute for shipping shirt box that goes out alone
- Rigid greyboard 36pt or 48pt for premium shirt packaging
- Cardstock 16pt to 24pt for lighter carton work
We would not go under 16pt on a lid and base. A thin lid bows in the middle and it looks cheap the second someone picks it up.
Finishing Options
- Matte lamination, resists finger marks on white board
- Soft touch for a premium shirt box
- Spot UV over the logo
- Foil stamping, gold and silver both work well here
- Emboss or deboss on kraft
- Printed inside panel, it gets photographed more than you think
Inserts And Extras
You can add collar supports, tissue wraps, belly bands, care cards, dividers and ribbon ties to custom shirt boxes for better organization, protection, and presentation.
- Collar support and tissue wrap
- Belly band or sticker seal
- Size guide and care card
- Divider when two shirts share one shirt packaging
- Ribbon tie for gift sets
Greener Choices
ZEE Packaging offers more sustainable shirt packaging options that help reduce excess material and shipping space.
- Recycled kraft shirt box with no film
- FSC certified board, certificate on request
- Soy based ink
- Paper tape instead of plastic
- Right sized shirt packaging so you ship less air
How We Work
- 100 unit minimum on any shirt box design
- Free 3D mockup and flat proof
- Free dieline from our inhouse designer
- 5 to 8 business day urgent turnaround
- Free shipping worldwide
Frequently Asked Questions
Lid and base or mailer for online orders?
Mailer, most of the time. It survives courier handling better and your packer doesn't need tape. Lid and base is lovely in store but it needs an outer shipper.
Will the collar get crushed?
Not with the right depth and a collar support. Undersized shirt packaging is the usual reason a collar arrives flat.
Can you do a window on the lid?
Yes, with clear PET patch or as a plain die cut if you want it fully recyclable.
Does white board mark easily in transit?
It can. Matte lamination handles scuff and finger marks far better than uncoated stock.
What do you charge for a shirt box?
Our shirt box packaging starts from $0.50 to $2.30 per unit for folding carton, $1.10 to $5.70 for mailer and $2.50 to $8.20 for rigid at moderate quantity. Foil and ribbon add to that. Shipping is included in our price. This is estimate only, so ask our team for an exact quote.
Do you supply tissue and bands too?
We do. Lots of clients order the box, tissue and belly band in one job so everything matches.
Can two shirts go in one box?
Yes, we just add depth and usually a divider so the folds don't press into each other.
