Custom Apparel Packaging
These apparel packaging made to fit your clothing, in ready sizes or built to your exact measurements, so every piece arrives looking just as good as it left you.
Configure & Order
Choose Your Apparel Box
Whatever you sell, from tees and knitwear to jackets and accessories, your apparel packaging can be sized to fit and printed to feel like your brand. Order one box to check the fit and print, or scale up to wholesale when you are ready.
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Folding Caron
Lightweight board for retail boxes and lighter products. Clean print surface, cost-effective at volume.
Corrugated
Fluted board with real crush protection in multiple flute grades. The workhorse for shipping and mailers.
Rigid
Thick chipboard with a premium, weighty feel. Built for gift-tier and higher-priced products.
Kraft
Recyclable, natural-brown board with a tactile, unbranded feel. The default for eco-first brands.
Material
Stock Type and Thickness
A box is only as good as the board it’s cut from. Here are the four stocks we run; pick by how your product ships and how you want it to feel.
Why Choose Us
Present your small business as a Brand
You don’t need an enterprise budget to look like an established brand. We handle the structure, the print, and the finish so your packaging earns its place on the shelf and in the unboxing.
Packaging strategies
We help you pick the box, stock, and finish that fit your product and your margins. Not the most expensive option; the right one
Idea to Production
Bring a rough concept, or a competitor's box you want to beat. We turn it into a manufacturable design with real specs.
In-House Design & Artwork
Our designers build your dieline and artwork in-house. No outsourced middle layer, no guesswork on print-readiness.
Prototypes & 3D Mockups
See your box as a 3D mockup, then order a physical prototype before you commit to a full run.
Worldwide Delivery
We manufacture direct and ship to 100+ countries, with quality checked before anything leaves the floor.
Free & Reliable Shipping
Free shipping on bulk orders, tracked to your door, on the turnaround we quote.
Apparel Packaging Guide
Custom Apparel Packaging for Clothing, Footwear & Accessories
Packaging is the first physical thing a customer touches from an apparel brand, and in a category where garments are folded, shipped, and returned more often than almost any other, it has to do more than look good on arrival. It has to fit the garment, protect the fabric, survive a return trip, and — increasingly — prove the item inside is genuine.
Custom apparel packaging for clothing, footwear, and accessories, including the anti-counterfeit and tamper-evident features that usually sit behind a five-thousand-unit minimum somewhere else.
Security Features at Any Order Size
That minimum is the real barrier for most small apparel brands. Serialized authentication tags, tamper-evident seals, and void labels are standard offerings at volume, but a brand ordering fifty boxes is normally told to come back when it’s bigger. Because there’s no minimum order here, a fifty-unit run can carry the same authentication features as a fifty-thousand-unit run — which matters in a category where counterfeits and return fraud hit small brands just as hard as large ones, and arguably hurt them more.
Anti-Counterfeit and Tamper-Evident Options
Clothing is a common target for return fraud, usually in one specific form: a customer buys a genuine item, swaps it for a counterfeit or a worn one, and returns the substitute for a refund. Because apparel returns are routine and expected, the swap often goes unnoticed. Packaging that makes tampering visible is the cheapest defense available — it doesn’t stop the fraud attempt, but it makes the attempt obvious at the point of intake instead of three steps later.
The general principle worth borrowing from higher-security industries is layering: combine one feature a customer can see and check without any equipment with one that’s harder to replicate. A single feature on its own is easier to work around than two used together.
Tear Strips, Void Labels, Serialized Tags
A tear-strip seal is the simplest option — a perforated strip that has to be destroyed to open the box, so a box that arrives intact is provably unopened. Void labels go a step further: placed across the seam, they fracture or leave a visible VOID pattern behind when peeled, so resealing a box doesn’t hide that it was opened. These are typically made from destructible vinyl or fragile paper substrates specifically so they can’t be lifted cleanly and reused, and they’re inexpensive — generally in the range of a cent to eight cents per seal depending on substrate and printing.
Serialized QR codes and NFC tags are the higher-end option. Each unit carries a unique code the customer or your own intake team can scan to verify against your records, which covers both authenticity checks and warranty tracking. Some NFC constructions are designed so the chip stops working if the tag is removed, which prevents counterfeiters from harvesting genuine packaging and reusing it on fake goods.
Choosing Security Features by Risk and Budget
Not every brand needs every feature. This is roughly how the options compare:
A practical starting point for most small brands is a void label plus a serialized QR code — one visible deterrent and one verifiable record, without the cost of NFC hardware on every unit.
Materials for Everyday vs. Premium Apparel Lines
Kraft and corrugated cover the majority of apparel shipping. Kraft mailers suit lightweight, foldable items — tees, leggings, casual basics — where the garment isn’t at risk of being crushed and shipping weight matters more than structure. Corrugated mailer boxes, typically in E-flute or B-flute, are the standard for heavier or structured pieces: coats, knitwear, denim, footwear. The added rigidity resists bending and stacking damage, and corrugated remains one of the most widely recycled packaging materials in the US, with recovery rates reported between roughly 71% and 76%.
Rigid board wrapped in printed paper is the premium tier. It costs meaningfully more and weighs more, so it’s worth the upgrade specifically where the box contributes to the product’s value — bridal and formal wear, limited collections, gift sets, or anything a customer is likely to keep rather than recycle. SBS board sits between the two, giving a smooth, bright printing surface for folding cartons without the cost or bulk of full rigid construction.
One structural option worth knowing about: rather than paying for a rigid box to do both jobs, some brands split the roles — a printed folding carton or sleeve handles presentation, and a plain corrugated mailer handles protection in transit. This often produces a better result than a single premium box trying to survive shipping while also looking boutique on arrival.
Format Comparison: Mailer, Corrugated Box, Rigid Box
Protecting Fabric: Interior Finishing and Fit
Two fabric-specific risks are worth designing around. First, rough interior edges, exposed staples, or unfinished die-cuts can snag knitwear and anything with loose threads — a smooth interior finish avoids this entirely, and it’s worth specifying explicitly rather than assuming. Second, garments with hardware — buttons, zippers, buckles, belt hardware — can puncture or tear thinner packaging from the inside during transit, which is a straightforward argument for corrugated over a flexible mailer on those SKUs.
Fit matters for a different reason. A box with too much empty space lets a folded garment shift and arrive creased, which reads as low quality regardless of the actual product. It also increases dimensional-weight shipping costs on every order. Right-sizing the box to your typical order is one of the few packaging decisions that improves presentation and reduces cost at the same time.
Natural-fiber garments — cotton, linen, wool — also benefit from packaging that doesn’t trap moisture, since long transit times in a sealed, humid package can produce a mildew smell on arrival even when nothing is visibly wrong.
Designing for Returns
Apparel has one of the highest return rates in retail, largely because fit can’t be confirmed before purchase. That makes resealability a functional requirement in this category rather than a presentation nicety. A mailer with a built-in second adhesive strip, or a box with a locking tab that closes cleanly a second time, means a customer can return an item without hunting for tape or a replacement box — which reduces return friction, and reduces the number of returns that arrive damaged because they were repacked badly.
There’s a tension worth naming here: a tamper-evident tear strip is designed to be destroyed on opening, which works against easy resealing. The usual resolution is to put the security feature on the inner presentation layer or on a sealed garment pouch, and keep the outer shipping box resealable — so the authenticity check survives while the return path stays simple.
Presentation Add-Ons: Tissue, Ribbon, Hang Tags
Most of the perceived quality of an unboxing comes from the inner layers rather than the outer box. Printed tissue paper keeps a garment folded and adds a sense of care at low cost. A branded sticker sealing that tissue, a ribbon closure, or a small insert card makes the parcel feel finished. Branded hang tags and swing tags carry sizing and care information while reinforcing the brand at the point the customer first handles the garment.
Finishing on the box itself — spot UV, foil stamping, embossing, debossing, soft-touch lamination — is available across most formats, with some limitations on corrugated where the fluted surface affects how fine detail holds. These add less cost than most brands expect and do a lot of the work in making packaging feel considered rather than generic.
Window cutouts are worth mentioning separately: a die-cut window with a clear film insert lets a customer or retail buyer see the garment without opening the box, which is useful for shelf display and for reducing handling on returns-sensitive stock.
Not sure which spec fits your product? Talk to our packaging team and Packaging Suppliers will help you choose board, size, and finish.
Foil Stamping
Add a metallic or holographic sheen to your logo or key elements. Foil catches the light and signals premium the second a customer picks up the box.
- Gold, silver, rose gold, holographic, and more
- Works on every box style and material
- Pairs cleanly with matte lamination
- No extra setup fee on standard foils
Emboss/Deboss
Press your logo or pattern into the stock for a raised or recessed texture customers feel before they read it. No ink; the impression does the work.
- Single-level or multi-level dies
- Works on Kraft, SBS, and rigid stock
- Pairs with foil for a tactile, premium hit
- Best on uncoated and matte surfaces
Lamination
A protective film over the printed surface that locks in the finish and guards against scuffs, moisture, and handling.
- Matte for a soft, muted look
- Gloss for high shine and color pop
- Soft-touch for a velvet feel
- Extends durability on shipping and retail boxes
Spot UV
A high-gloss coating on select areas: logo, title, pattern; for sharp contrast against a matte background.
- Gloss-on-matte contrast
- Highlights logos and key artwork
- Pairs with soft-touch lamination
- Registered precisely to your dieline
Custom Inserts
Fitted inserts that hold product in place, cut movement in transit, and control the reveal on opening.
- Foam, corrugated, or paperboard
- Cut to your exact product dimensions
- Protects fragile and multi-piece items
- Builds a deliberate unboxing sequence
Custom Styles
A cut-out with clear film so customers see the product without opening the box, built for retail shelves.
- PET or PVC film options
- Any shape, sized to your dielines
- Ideal for food, cosmetics, and gifts
- Balances protection with visibility
Unlimited Customizations
Every Detail, Your Way
Endless finishing options so your product packaging looks exactly how you imagined it — and then some.
Packaging Made Easy.
Four steps, no back-and-forth. Send your spec or a rough idea. We build the dieline and a 3D mockup for your approval, print and produce with a color check before the run, and ship to your door. You get one dedicated contact the whole way, someone accountable, not a ticket queue.
Customer Stories
Brands That Trust P&S
From boutique fashion labels to fast-growing DTC brands; here’s what our customers are saying.
“The magnetic closure boxes for our accessory line look absolutely stunning. The foil stamping on our logo is better than anything I’ve seen at twice the price.”
Michael Schmidt.
Founder, Bloom Apparel Co.
“We switched to P&S for our clothing boxes and the difference was immediate. Our customers now post unboxing videos without asking, says everything.”
Owner, STD Leather Co.
“As a shoe brand, I was nervous about minimums and quality. P&S had no MOQ and the shoe boxes arrived within time, perfect quality, every single time.”
CEO, Strider Footwear.
Common Questions
Frequently Asked Questions
Everything you need to know about ordering custom apparel packaging.
What kind of box works best for shipping clothes?
For most clothing brands a sturdy mailer box does the job, since it ships on its own and holds folded pieces without a second outer box. We size it to your fold so nothing slides around on the way.
Can you make apparel boxes for bulkier items like hoodies or denim?
Absolutely. We build to your folded garment, so heavier knits and denim get the extra depth they need instead of being squeezed into a box that is too flat.
Will the packaging keep knitwear and delicate fabrics safe?
Yes, the inside is finished so it will not catch on knit loops or leave marks on soft fabric. You can pick a smooth laminated or a natural uncoated inside depending on what you ship most.
What is the difference between everyday and premium apparel boxes?
Everyday orders usually go in a printed mailer box that protects and brands in one piece, while premium lines and gift drops often use a rigid box for that heavier, more special feel when the customer opens it.
Do you make packaging for different types of clothing?
We do, from flat boxes for tees and accessories to deeper ones for activewear sets and chunky knits. Just tell us what you are shipping and we will match the size and style to it.
Can I get a sample before placing a bulk order?
Yes. Order a sample or a sample kit to check the stock, print, and fit around your garment before committing to a full run.
What materials do you use?
Kraft, corrugated in multiple flute grades, rigid chipboard, and SBS — every material except plastic film. Corrugated is the default for shipping mailers; rigid suits premium and gift-tier lines.
What file formats do you accept for artwork?
Print-ready vector files work best: AI, PDF, or EPS with outlined fonts. High-res PSD works too. Not sure? Send what you have and our design team preps it.
How long does production and delivery take?
4–8 business days from proof approval, plus shipping. Rush options are available for tight launch or campaign dates.