Shipping Apparel: Best Practices for Clothing E-commerce

Apparel is one of the most commonly shipped e-commerce categories, but it comes with unique challenges. From maintaining garment quality to creating brand experiences, this guide covers everything you need to know about shipping clothing effectively.

Apparel Shipping Challenges

Common Issues

Quality concerns:

• Wrinkles and creases
• Damage during transit
• Color transfer between items
• Odors from packaging
• Humidity and moisture damage

Business challenges:

• High return rates (30-40% in fashion)
• Sizing-related returns
• Presentation expectations
• Packaging costs vs. brand experience
• Seasonal volume fluctuations

Industry Statistics

Apparel e-commerce shipping:

• Return rates 3x higher than other categories
• 52% of returns due to fit issues
• Presentation impacts brand perception significantly
• Packaging influences repeat purchases
• Shipping speed increasingly important

Packaging Options for Apparel

Poly Mailers

Best for:

• T-shirts, casual wear
• Non-delicate items
• Cost-conscious shipping
• Lightweight garments

Advantages:

• Lowest cost
• Lightweight (reduces shipping cost)
• Water-resistant
• Available in many sizes

Disadvantages:

• Less protection
• Can cause creasing
• Less premium feel
• Limited branding options

Paperboard Mailers

Best for:

• Mid-range apparel
• Items needing flat shipping
• Eco-conscious brands
• Better presentation

Advantages:

• Recyclable
• Better protection than poly
• Good for folded items
• Rigid protection

Disadvantages:

• Higher cost than poly
• Not water-resistant
• Limited sizes available

Boxes

Best for:

• Premium/luxury items
• Multiple items per order
• Delicate garments
• Structured clothing

Advantages:

• Best protection
• Premium presentation
• Branding opportunities
• Structured items stay flat

Disadvantages:

• Higher shipping cost (DIM weight)
• More material cost
• Storage space needed
• Environmental impact

Garment Bags

Best for:

• Formal wear
• Suits and dresses
• High-value items
• Items needing hang transport

Advantages:

• Protects from wrinkles
• Professional presentation
• Can be shipped hung
• Reusable by customer

Disadvantages:

• Higher cost
• Larger package size
• Special handling may be needed

Folding and Packing Techniques

Basic T-Shirt Fold

Steps:

Lay shirt face down

Fold sleeves to center

Fold in half lengthwise

Fold in half or thirds (depending on mailer size)

Place fold side up in package

Tips:

• Consistent folds create efficiency
• Train all staff same technique
• Use folding board for uniformity
• Face design outward when possible

Pants and Jeans

Method:

Fold in half lengthwise (leg to leg)

Fold in half or thirds depending on length

Roll for tight packaging or lay flat

Considerations:

• Heavier items - consider box
• Buttons/zippers facing inward
• Protect decorative elements

Dresses and Formal Wear

Best practices:

• Use tissue paper between folds
• Minimize fold points
• Consider garment bags for premium
• Stuff with tissue to maintain shape
• Protect embellishments

Outerwear and Jackets

Approach:

• Fold sleeves to center
• Fold in half or thirds
• Use larger packaging
• Consider rolling for some styles
• Protect zippers and hardware

Creating Brand Experience

Unboxing Presentation

Elements to consider:

• Branded tissue paper
• Logo stickers or tape
• Thank you cards
• Brand inserts
• Consistent color scheme

Balance considerations:

• Cost per package
• Brand positioning
• Customer expectations
• Environmental impact

Tissue Paper Usage

When to use:

• Premium items
• Gift packaging
• Wrapping for protection
• Color contrast/presentation

Eco-friendly alternatives:

• Recycled tissue
• Paper-based wrapping
• Minimal packaging approaches
• Compostable options

Thank You Cards and Inserts

Include:

• Thank you message
• Care instructions
• Return/exchange information
• Social media handles
• Loyalty program info
• Discount for next purchase

Keep it simple:

• One card, multiple purposes
• QR codes for digital info
• Recyclable materials

Reducing Apparel Returns

The Fit Problem

Why people return clothes:

• Too small: 30%
• Too large: 22%
• Didn't match photos: 20%
• Quality not as expected: 15%
• Changed mind: 13%

Prevention Strategies

Sizing solutions:

• Detailed size charts
• Model measurements provided
• Fit guides (runs small/large)
• Size comparison tools
• Customer reviews with size info
• Virtual try-on technology

Product presentation:

• Multiple photos (front, back, detail)
• Photos on diverse body types
• Accurate color representation
• Fabric close-ups
• Video showing movement/fit

Description quality:

• Fabric content and feel
• Stretch/no stretch
• Weight of fabric
• True-to-size notes
• Styling suggestions

Returns Management

Easy Return Process

Best practices:

• Include return label in package
• Clear return instructions
• Easy online return initiation
• Multiple return options
• Fast refund processing

Return packaging:

• Reusable outbound packaging
• Self-sealing return envelopes
• QR codes for label printing
• Drop-off locations

Processing Returns

Workflow:

Receive and log return

Inspect garment condition

Categorize (restock, outlet, donate)

Process refund/exchange

Repackage for resale if applicable

Quality assessment:

• Worn or damaged
• Missing tags
• Odors or stains
• Sellable condition
• Outside return window

Cost Optimization

Weight Reduction

Strategies:

• Lightest appropriate packaging
• Avoid overpackaging
• Remove unnecessary hangers/tags
• Consolidate multi-item orders
• Use poly mailers when appropriate

Right-Size Packaging

Multiple sizes needed:

• Small poly mailer (t-shirts)
• Medium mailer (pants, tops)
• Large mailer (dresses, jackets)
• Small box (delicates, multiple items)
• Large box (outerwear, large orders)

Dimensional weight impact:

• Oversized packaging costs more
• Train staff on size selection
• Audit packaging choices regularly

Carrier Selection

Consider by item type:

• USPS First Class: Light items under 1 lb
• USPS Priority: Standard apparel
• Ground services: Heavy items, boxes
• Express: Rush orders only

Seasonal Considerations

Summer Shipping

Challenges:

• Heat in delivery trucks
• Humidity concerns
• Lighter items (lower costs)

Solutions:

• Breathable packaging
• Avoid heat-sensitive materials
• Faster shipping in extreme heat

Winter Shipping

Challenges:

• Weather delays
• Moisture/snow exposure
• Holiday volume spikes

Solutions:

• Water-resistant packaging
• Communicate about delays
• Plan for peak season

Holiday Peak

Preparation:

• Stock extra packaging
• Hire seasonal staff
• Communicate shipping deadlines
• Extend return windows
• Offer gift packaging options

Specialty Apparel Shipping

Athletic Wear

Considerations:

• Technical fabrics care
• Moisture-wicking protection
• Compact folding possible
• Often lighter weight

Formal Wear

Requirements:

• Premium packaging
• Minimal folding
• Garment bags when needed
• Insurance for high value
• White glove options

Children's Clothing

Notes:

• Smaller sizes = easier shipping
• Multiple items per order common
• Safety tag requirements
• Gift shipping frequent

Plus Size

Shipping considerations:

• Larger package sizes needed
• Weight considerations
• Variety of packaging sizes
• Folding technique adjustments

Sustainable Apparel Shipping

Eco-Friendly Materials

Options:

• Recycled poly mailers
• Paper-based mailers
• Biodegradable bags
• Recycled cardboard
• Plant-based packaging

Reducing Waste

Strategies:

• Right-size packaging
• Eliminate unnecessary inserts
• Digital receipts vs. paper
• Reusable packaging programs
• Minimal void fill

Customer Communication

Messaging:

• Highlight sustainable choices
• Recycling instructions
• Offset options
• Brand commitment info

Technology Solutions

Shipping Software

Features for apparel:

• Rate shopping by weight/size
• Batch processing
• Return label generation
• Packing slip customization
• Integration with platforms

Inventory Management

Important features:

• Size/color variant tracking
• Low stock alerts
• Seasonal inventory planning
• Returns processing
• Multi-warehouse support

Quality Control

Pre-Ship Inspection

Checklist:

• Correct item and size
• No defects or stains
• Tags attached
• Proper folding
• Complete order
• Correct packaging

Staff Training

Train on:

• Consistent folding techniques
• Quality identification
• Packaging selection
• Presentation standards
• Handling delicates

Key Takeaways

Match packaging to product: Premium items need premium packaging

Reduce returns proactively: Better photos, sizing, descriptions

Create experience: Unboxing matters for brand perception

Optimize costs: Right-size packaging, appropriate shipping methods

Plan for seasonality: Holiday prep is essential

Process returns efficiently: High return rates require good systems

Consider sustainability: Eco options increasingly expected

Train your team: Consistency in packing and quality

Apparel shipping requires balancing cost efficiency with brand experience and garment protection. Invest in the right packaging, create efficient processes, and focus on reducing returns through better product information.