We’ve all received clothing items purchased online that are packaged in plain or printed poly bags. There’s often a hole in the bag, and the presentation leaves much to be desired. Not to mention the sustainability elephant in the room.
Lawmakers are cracking down on truth in labeling and transparency regarding manufacturers and claiming their plastic products are recyclable. SB 343 in California may just be the start of a wider trend to shift away from deceptive labeling. We’ve long made the claim that not all “recyclable” packaging is created equally. In 2026, if you want your brand to stand out as a sustainable, eco-conscious company, then you really should be using paper-based packaging products to promote ease of recycling. For clothing/apparel brands in particular, your paper packaging options are many, and they can all be customized and attractive, without significantly increasing your overall packaging cost.
Custom Corrugated Die Cut Mailer Boxes
You may not think a box is needed for smaller, lightweight clothing items such as socks, gloves, hats or t-shirts, but the fact is we have created mailer boxes for each of these products. We will also admit that we are the first people to tell you when a box is not needed, and suggest alternative options like those listed in the paragraphs below. However, for heavier, bulkier items like jackets, hoodies, jeans, dresses, sweatshirts and more, a box is likely the best packaging solution. We have worked with hundreds of clothing brands over the years, and it’s extremely likely we have an existing size that would work for your products. Many heavier clothing items would benefit from the protection of a corrugated box, and provide a much better experience for your customers as opposed to a flimsy poly bag.
Custom Corrugated RSC Boxes
Whether or not an RSC or die cut mailer box is better for your product is typically a matter of your customer order history, case sizes/counts and product size. If you are packing a large, bulky winter coat, for example, you would be best served to utilize an RSC. Die cut mailers tend to really increase in cost at larger sizes (anything over 4’’ in depth, for example) due to the amount of scrap/board involved as you scale up. The cutting die cost on a corrugated mailer also needs to be considered, as well as a (likely) higher per unit cost. An RSC box can be made with no tooling, and the cost generally is lower by comparison, even at large sizes. The same is true if you are selling a smaller clothing item, but selling it as a 3 pack, or 5 pack for example that would require a large size.
Unpadded Paper Mailer Envelopes
The perfect packaging solution for smaller, lightweight, single clothing or accessory items. Paper mailers can be custom printed BY THE CASE, either as a 1 or 2 color flexo print, or as a beautiful digital print on either kraft or white. Paper mailers are made of a strong, durable paper grade that will protect products from shipping elements and deliver a great presentation to your customers. Envelopes can be a much lower cost alternative to boxes, especially when you consider they are shipped and stored flat. When you seal them closed you can essentially form fit the mailer to the product, eliminating any potential of shipping air, greatly reducing your shipping costs.
As mentioned, we have worked with hundreds of clothing/apparel brands in our nearly two decades in business. We’d love to start you on your own packaging journey.
Please Contact Us Today
If you haven’t worked with us before, please reach out to us for a no cost, no obligation packaging consultation. As always, if you have any questions, one of our branded packaging advisors is standing by to assist, with decades of experience behind them. Please call us at 630-551-1700 or contact us via email at www.SalazarPackaging.com.
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https://www.salazarpackaging.com/custom-packaging-for-apparel-and-clothing/
https://www.salazarpackaging.com/guidelines-for-shipping-e-commerce-dtc-athleisure-clothing/
https://www.salazarpackaging.com/buyers-guide-branded-e-commerce-packaging-clothing/