Custom Underwear Boxes & Underwear Packaging
Shoppers in this aisle decide fast. Fabric, fit, price, done. The carton has maybe two seconds to communicate all three, and it has to do that at a unit cost that keeps your margin alive. That tension is the whole job, and it is what we work through with every client who comes to us for underwear packaging at ZEE Packaging.
Retail Shelf Or Doorstep
At ZEE Packaging, you can create custom underwear boxes to the sales channel, using mutiple box styles based on how the product will be sold and delivered.
- Peg display needs a euro hole or hang tab and a stiffer panel
- Shelf facing front panel does the selling, window helps
- Ecommerce mailer no window, focus on the unboxing side of underwear packaging
- Subscription drop slim mailer, low weight, cheap to post
- Gift and holiday rigid or drawer style at a higher price point
Tell us where it is going and we build the underwear box for that channel rather than a compromise between both.
Pack Count Drives The Size
ZEE Packaging creates custom underwear boxes around the folded garment and pack count. We create packaging that fit single pieces, multipacks, gift sets, and mailer formats without unnecessary space.
- 5" x 4" x 1" for a single brief or trunk
- 6" x 5" x 1.5" for two pack
- 7" x 5" x 2" for three pack underwear packaging
- 8" x 6" x 2.5" for five pack
- 9" x 7" x 2" for a boxed gift set
- 10" x 8" x 2" for mailer style
Fold one the way your packer really does it, measure, then send us the numbers and we draw the dieline around it.
Board, And Where Brands Cut Too Deep
At ZEE Packaging, you can select board thickness for custom underwear boxes based on pack count, box size and display method.
- 14pt to 16pt for a single pair underwear box
- 18pt to 20pt once you get to three and five packs
- SBS C1S for smooth print heavy underwear packaging
- Kraft board for organic cotton and bamboo ranges
- Corrugated E flute for shipping cartons
- Rigid greyboard 36pt for gift sets
We get a lot of brands arriving after a supplier put them on 12pt to save a cent. It proofs fine, then a five pack sags in the middle on the peg. Honestly it is not a saving worth making.
Showing The Fabric
ZEE Packaging can add clear PET windows, open die cuts or touch-friendly swatch openings to custom underwear boxes so shoppers can better see and feel the product before buying.
- Die cut window with clear PET patch, standard on retail underwear packaging
- Open die cut with no film, cheaper and fully recyclable
- Full bleed fabric photography instead of a window
- Swatch cut out so buyers can actually touch the material
Print And Finish
- Matte lamination, hides finger marks better than gloss
- Soft touch on premium underwear boxes
- Spot UV over the logo
- Foil stamping for gift and seasonal underwear packaging
- Emboss or deboss on kraft
- Inside print, costs almost nothing and it gets noticed
Copy That Has To Be On Pack
Plan your underwear box panel around essential information.
- Size and fit clearly on the front face
- Fabric composition and care symbols
- Country of origin, brand name and address
- Barcode with proper quiet zone
- Style or batch code space
Our prepress team checks every panel against the dieline so nothing important gets trimmed at the edge.
Greener Choices
- Recycled kraft underwear box with no film
- FSC certified board, certificate on request
- Soy based ink
- Plain die cut window instead of PET
- Right sized underwear packaging so you ship less air
Working With Us
- 100 unit minimum on any underwear box design
- Free 3D mockup and flat proof
- Free dieline from our own designer
- 5 to 8 business day urgent turnaround
- Free shipping worldwide
Frequently Asked Questions
Euro hole or hang tab?
Euro hole if the board is 18pt or above, it is cheaper and cleaner. Hang tab if you are on thinner stock, because a punched hole tears out on light board.
Which style handles a five pack best?
Auto lock bottom or seal end. Both hold the weight properly and your packer doesn't need tape or extra folding time.
How much does an underwear box run?
Rough estimate is $0.22 to $1.75 per unit for folding cartons, $1.85 to $5.10 for mailers and $2.00 to $8.80 for rigid gift boxes at moderate quantity. Window patch and foil add to that. Shipping is included in our price. This is an estimate only, so ask our team for an exact quote.
Can you do a soft touch finish at low cost?
Soft touch adds a bit but on a gift line it usually pays for itself. For everyday multipacks we normally suggest matte instead.
Does the window have to be plastic?
No. A plain die cut opening works fine and keeps the whole underwear box recyclable, you just lose the dust protection.
How do you keep multipacks neat inside?
Right sizing does most of the work. A belly band or a simple paperboard divider handles the rest for very little cost.
Do you supply hang tags and stickers as well?
We do. Lots of clients order cartons, tags and seals in one job so the colors match across everything.
