Apparel and D2C brand packaging
Apparel ships flat and light. A folded garment weighs little and takes almost no crush load, so the packaging stops being just protection and becomes the brand. The box is the first physical thing your buyer touches. Vikrama Industries makes printed corrugated mailers to your size, so the garment arrives uncreased, dry through the monsoon, and inside something worth photographing.
Poly mailer vs printed corrugated mailer
Most apparel brands start in a poly bag. It is cheap and light, but it crushes, creases and reads as generic. A printed corrugated mailer costs more per unit and does more work: it protects, it brands, and it survives a return trip. Here is the same shipment two ways.
For apparel the box is the first physical thing the buyer touches. It sets the brand before the garment is even unfolded.
The poly bag is not wrong for every product. But for a brand that wants recall and a clean returns experience, the corrugated mailer earns its cost.
Sizing the box for a folded garment
A garment folds to a flat pad. The mailer should match that pad plus a little room, so the fold stays put and the box stays slim for the courier. Below is starting guidance. Every VI box is made to your exact size, so treat these as a beginning, not a catalogue.
| Garment | Folded pad (approx cm) | Suggested mailer L x W x H (cm) | Ply |
|---|---|---|---|
| T-shirt or top | 24 x 20 | 26 x 22 x 4 | 3-ply |
| Shirt or kurta | 28 x 24 | 30 x 26 x 5 | 3-ply |
| Pair of jeans | 30 x 26 | 32 x 28 x 7 | 3-ply or 5-ply |
| Hoodie or sweatshirt | 32 x 28 | 34 x 30 x 9 | 5-ply |
| Two-piece set | 34 x 28 | 36 x 30 x 10 | 5-ply |
A slim, well-fitted mailer also keeps volumetric weight down: couriers bill length times width times height in centimetres divided by 5000, against the actual weight, and charge the greater. A flat garment box stays close to its real weight.
What the box has to do for a D2C brand
- Hold the fold flat so nothing arrives creased.
- Resist monsoon damp with a corrugated board, not a thin film.
- Carry brand print outside and a message or size guide inside.
- Feel worth photographing for the unboxing moment.
- Reship cleanly when a size has to go back.
Print level is yours to set: plain kraft, one or two brand colours, or full outside coverage with an inside print. The quote engine prices on size, ply, quantity and print level, so you can weigh a heavier print against your unit budget.
From spec to doorstep
- Share your garment and fold, or WhatsApp a photo of the current pack.
- Get a live price band on size, ply, quantity and print level.
- A human confirms the exact figure usually in minutes, always within 24 hours.
- Approve a physical sample, including the print.
- Production runs in NCR and dispatches pan-India with tracking. GST invoice issued.
The quote is a band, not a fixed figure, because recycled kraft trades roughly Rs 38 to Rs 46 per kg with the market. A human pins the exact number for your run on WhatsApp.
Frequently asked questions
Is a corrugated mailer worth it over a poly bag?
For a brand that wants recall and clean returns, usually yes. The corrugated mailer holds the fold flat, resists damp, carries your print, and reships cleanly. The poly bag is cheaper but generic and offers little protection.
Will my garment arrive creased?
A mailer sized to the folded pad holds the garment still, so it does not shift and crease in transit. Share your fold size and a human will confirm the box dimensions.
Does corrugated hold up in the monsoon?
Corrugated board resists damp far better than a thin film. For high-humidity routes, mention it and the ply and print can be set with that in mind.
Can I print inside the box as well as outside?
Yes. Brand print goes outside and a message, size guide or care note can go inside. Print level is part of the quote, and you approve it on the sample.
What size box do I need for a T-shirt?
A folded T-shirt sits around 24 by 20 cm, so a mailer near 26 x 22 x 4 cm in 3-ply is a common starting point. Every box is made to size, so we tune it to your exact fold.
How do I get an exact price?
The quote engine gives a live band on size, ply, quantity and print. A human then confirms the exact figure usually in minutes, always within 24 hours on WhatsApp, and you approve a sample before production.
Get your box priced in 30 seconds.
Enter your spec for a live estimate band, or send it straight to WhatsApp. A human engineer confirms the exact number, usually in minutes, always within 24 hours, 7 days a week.