Shipping Packaging Materials: Complete Guide to Boxes, Mailers, and Supplies

Choosing the right packaging protects your products and affects your shipping costs. This guide covers all packaging materials and helps you make smart choices.

Types of Shipping Containers

Corrugated Boxes

Box Types

• Regular Slotted Container (RSC): Most common
• Half Slotted Container (HSC): Open top
• Full Overlap (FOL): Extra protection
• Die-cut boxes: Custom shapes

Corrugated Strength

• Single wall: Light to medium items
• Double wall: Heavy items
• Triple wall: Industrial/freight

Edge Crush Test (ECT)

• 32 ECT: Standard (up to 40 lbs)
• 44 ECT: Heavier items
• 48 ECT: Very heavy
• 65+ ECT: Industrial

Choosing Size

• Allow 2" on each side for padding
• Avoid excessive empty space (DIM weight)
• Consider product dimensions

Poly Mailers

Best For

• Soft goods (clothing, fabric)
• Non-fragile items
• Books and magazines
• Cost-sensitive shipping

Features to Consider

• Thickness (2.5 mil standard, 3 mil premium)
• Self-sealing adhesive
• Tear resistance
• Weather protection

Sizes

• 6×9: Small items
• 10×13: T-shirts, small clothing
• 14.5×19: Larger clothing
• 19×24: Bulky soft goods

Padded Mailers

Types

• Bubble mailers: Most protective
• Paper padded: Eco-friendly
• Kraft mailers: Basic protection
• Poly bubble: Weather resistant

Best For

• Small electronics
• Jewelry
• Cosmetics
• Small fragile items

Rigid Mailers

Best For

• Documents that can't bend
• Photos and prints
• Thin books
• Certificates

Options

• Stay flat mailers
• Photo mailers
• Book mailers

Protective Materials

Bubble Wrap

Types

• Small bubble (3/16"): Light cushioning
• Medium bubble (5/16"): Standard protection
• Large bubble (1/2"): Heavy items

Usage Tips

• Wrap items completely
• Bubbles facing in for gripping surface
• Secure with tape

Anti-Static Bubble

• For electronics
• Prevents static discharge
• Pink or blue colored

Packing Paper

Benefits

• Versatile
• Eco-friendly
• Good void fill
• No static concerns

Types

• Newsprint: Budget option
• Kraft paper: Cleaner look
• Tissue paper: Light items
• Honeycomb paper: Sustainable cushioning

Foam Materials

Foam Sheets

• Wrap individual items
• Layer protection
• Cut to size

Foam Pouches

• Pre-made protection
• Quick packing
• Various sizes

Foam-in-place

• Custom molding
• High-value items
• Industrial applications

Air Pillows

Advantages

• Lightweight
• Good void fill
• Cost effective
• Easy to use

Considerations

• Not for heavy items
• Can pop in transit
• Not eco-friendly
• Requires inflator machine

Packing Peanuts

Traditional (Styrofoam)

• Good cushioning
• Lightweight
• Not eco-friendly
• Static issues

Biodegradable

• Starch-based
• Dissolves in water
• Eco-friendly
• More expensive

Securing Materials

Packing Tape

Types

• Acrylic: General purpose
• Hot melt: Better adhesion
• Water-activated: Tamper evident
• Filament: Reinforced strength

Tape Width

• 2": Standard boxes
• 3": Heavy duty
• Custom width: Branding

Stretch Wrap

Uses

• Pallet wrapping
• Bundling items
• Waterproofing
• Tamper evidence

Strapping

Types

• Polypropylene: Light duty
• Polyester: Medium duty
• Steel: Heavy duty

Sustainable Packaging Options

Recyclable Materials

Options

• Corrugated cardboard
• Paper tape
• Paper void fill
• Recyclable poly mailers

Biodegradable Options

Materials

• Mushroom packaging
• Cornstarch peanuts
• Seaweed packaging
• Recycled paper products

Reducing Package Waste

Strategies

• Right-size packaging
• Eliminate unnecessary materials
• Use recycled content
• Communicate recyclability to customers

Packaging Cost Optimization

Buying in Bulk

Savings

• 20-50% off retail prices
• Lower per-unit cost
• Storage considerations
• Minimum order quantities

Custom vs Standard

Custom Packaging

• Better brand experience
• Higher cost
• Minimum orders
• Lead time required

Standard Packaging

• Lower cost
• Readily available
• No minimums
• Add branding with tape/labels

DIM Weight Considerations

Minimize Dimensional Weight

• Use smallest box possible
• Consider mailers vs boxes
• Custom box sizes
• Collapsible designs

Packaging by Product Type

Apparel

Recommended

• Poly mailers (primary)
• Tissue paper (optional)
• Poly bags for protection
• Boxes for formal attire

Electronics

Recommended

• Anti-static materials
• Foam cushioning
• Sturdy boxes
• Double boxing for fragile

Fragile Items

Requirements

• Bubble wrap wrapping
• Rigid outer box
• 2" cushioning minimum
• FRAGILE labeling

Heavy Items

Needs

• Double wall boxes
• Bottom reinforcement
• Weight limit compliance
• Strapping if needed

Supplier Recommendations

National Suppliers

• Uline
• The Packaging Company
• Paper Mart
• Staples
• Amazon Business

Cost-Saving Options

• Local restaurant supply stores
• Wholesale clubs (Costco)
• Recycled boxes
• USPS free Priority boxes

Investing in the right packaging materials protects your products, reduces damage claims, and can lower your overall shipping costs.