Mailer Box Size Chart for Indian D2C Brands
Pick a mailer that clears your product by about 5 to 10 mm on each side. VI's standard mailers run from 6x4x2 inches up to 14x10x4 inches, listed in both inches and millimetres. Smaller sizing and sensible ply hold volumetric weight down, so your courier slab stays lower.
How do you read this mailer box size chart?
This chart lists the mailer box sizes Vikrama Industries recommends as standards for Indian D2C brands. These are not official market sizes. They are the sizes we cut most often because they fit common products and hold up across Delhivery, Bluedart and DTDC networks. Every box is made to your exact size, so read the chart as a starting point, not a fixed catalogue. If your product sits between two rows, we adjust the exact figure on the quote engine before production.
All dimensions are internal, written as length x width x height. We show inches first because most brands brief us in inches, then millimetres, which is the canonical unit in our system. A mailer box folds flat, wraps around the product and self-locks with side wings. That construction suits apparel, cosmetics, books, phone accessories and small hardware, where you want a clean unboxing and a box that survives the last mile.
What are VI's standard mailer box sizes?
Here are eight sizes that cover most first orders. If your product falls between two rows, we size up by a few millimetres rather than forcing a tight fit that crushes the contents. The suggested flute is a starting grade: E flute at about 1.5 mm for light items, B flute at about 3 mm for everyday shipping, and C flute at about 4 mm when the contents are heavier or the route is long.
| Size in inches | Size in mm | Typical contents | Suggested flute |
|---|---|---|---|
| 6 x 4 x 2 | 152 x 102 x 51 | Jewellery, small cosmetics, accessories | E flute (1.5 mm) |
| 7 x 5 x 2 | 178 x 127 x 51 | Phone cases, soaps, sachets | E flute (1.5 mm) |
| 8 x 6 x 2 | 203 x 152 x 51 | Books, wallets, a single folded tee | E flute (1.5 mm) |
| 9 x 6 x 3 | 229 x 152 x 76 | Skincare sets, small electronics | B flute (3 mm) |
| 10 x 8 x 3 | 254 x 203 x 76 | Apparel, two-piece sets | B flute (3 mm) |
| 11 x 8 x 3 | 279 x 203 x 76 | Compact shoes, homeware | B flute (3 mm) |
| 12 x 9 x 4 | 305 x 229 x 102 | Hampers, bundled apparel | B flute (3 mm) |
| 14 x 10 x 4 | 356 x 254 x 102 | Large apparel, multi-item orders | C flute (4 mm) |
These are all 3-ply single wall unless the weight calls for more. A single wall mailer keeps volumetric weight low while giving enough stiffness for cushioned goods. For heavier bundles we move to 5-ply double wall at the same internal size, so the box stays the same on the outside but carries more load without bowing.
How do you pick a size from your product dimensions?
Sizing is simple. Measure the product at its longest, widest and tallest points. Add a small clearance so the box closes without crushing and without rattling. Then match the result to the nearest standard, or ask us to cut that exact figure. The steps below take under a minute per product.
- Measure the product in millimetres: length, width and height at the largest points.
- Add 5 to 10 mm to each dimension for clearance and any inner wrap.
- For soft goods that fold, add 10 to 15 mm to allow for bulk when packed.
- Round up to the nearest standard size, or request the exact cut from us.
- Check the volumetric weight before you commit: length times width times height in cm, divided by 5000.
A mailer that fits well clears the product by about 5 to 10 mm on each side, no more.
Extra clearance feels safe, but it costs you twice. It adds board area, which raises the unit price through our costing method, because the blank area is roughly (2*(L+W)+glue) times (W+H). It also adds volumetric weight, which the courier bills whether the box is full or not. A snug box is cheaper to make and cheaper to ship at the same time.
3-ply or 5-ply: which does a mailer need?
Most mailers ship in 3-ply single wall. It is light, prints cleanly and folds sharp. You step up to 5-ply double wall when the product is dense, when the box runs larger than about 12 inches on its longest side, or when the route is rough. Triple wall 7-ply is rarely needed for a mailer; that grade belongs to heavy shipping cartons, not the last mile of a single order.
Ply also interacts with monsoon humidity. Recycled kraft softens as it takes on moisture, so a box that felt firm in a dry warehouse can sag in transit during the rains. A slightly higher ply, or a moisture-aware liner, holds shape better on long routes. We flag this on the quote when the season and the destination suggest the extra protection is worth it.
How does box size change your courier bill?
Volumetric weight is where box size hits your invoice. Couriers charge the greater of actual weight and volumetric weight. For a light product in an oversized mailer, the volumetric figure wins, and you pay for the empty space. Trimming the box by a centimetre or two on each side can drop you a full slab on the courier rate card.
Couriers bill the greater of actual and volumetric weight; volumetric is L x W x H in cm divided by 5000.
So the size chart is also a cost tool. Pick the smallest standard that fits, keep the ply sensible, and the courier slab often drops by one level across the whole order. Our quote engine shows the price band as you change the size, ply and quantity, so you can test the trade-off before you order. A human confirms the exact figure on WhatsApp usually in minutes, always within 24 hours.
Frequently asked questions
Are these the only mailer sizes VI makes?
No. These eight are our recommended standards because they fit common products and print well, but every box is made to your exact size. If your product needs 265 x 190 x 70 mm, we cut that. The chart just gives you a fast starting point.
Should I measure in inches or millimetres?
Either works, since the quote engine is dual unit. We show inches first because most briefs come in inches, but millimetres are canonical in our system, so that is what we cut to. Measure however you are comfortable and we convert.
How much clearance should I add to my product size?
Add about 5 to 10 mm on each dimension for rigid items, and 10 to 15 mm for soft goods that fold and add bulk. More than that wastes board and raises volumetric weight, so the box costs more to make and more to ship.
Which flute should a mailer use?
E flute at about 1.5 mm suits small light items and gives a smooth print face. B flute at about 3 mm is the everyday choice for most mailers. C flute at about 4 mm is for heavier contents. We suggest a grade on the quote based on weight and route.
Do you approve a sample before the full run?
Yes. A physical sample is made and approved before any production run, so you check the fit, the print and the fold in your hand first. GST invoices are issued on every order, and dispatch is pan-India from our NCR unit.
How do I get a price for a custom mailer size?
Enter the length, width, height, ply, quantity and print level into the quote engine. It returns a live price band rather than a single figure, because kraft rates move with the market. A human confirms the exact number on WhatsApp usually in minutes, always within 24 hours.