Boxes vs Mailing Bags vs Padded Bags: Which to Use
Key Takeaway
How to choose outer packaging for each order: cardboard boxes for fragile or heavy goods, mailing bags for soft goods, padded bags for small hard items.
The outer layer is the packaging the courier handles. Pick one that is too big and you pay to post air; pick one that is too weak and you pay for returns. Most orders fit one of three options.
Cardboard boxes: for fragile, heavy or mixed orders
A box is the only option of the three that holds its shape under weight and can be stacked. Our single wall boxes (125KT B-flute) suit everyday parcels. Double wall boxes add a second fluted layer for heavier or more fragile goods. Check the maximum load on the specification sheet on each size (tap the product picture in the range table).
- Best for: glass, ceramics, tools, multi-item orders.
- Needs: tape to close, and usually some void fill inside.
Grey mailing bags: for clothing and soft goods
Grey mailing bags are light, flat and close with a self-seal strip, so there is no box to build and no tape. Because they add almost no size or weight, a folded garment can often go at a cheaper postal size than it would in a box.
- Best for: clothing, textiles, soft goods, items already in their own retail box.
- Not for: anything that can break or be crushed.
Jiffy padded bags: for small hard items
Jiffy padded bags have a paper padding layer between two paper walls. It resists sharp corners better than a plain plastic mailer, without the need for a separate box and filler.
- Best for: books, metal parts, spare parts, small hardware.
Quick decision guide
| If you are sending... | Use | Why |
|---|---|---|
| Something fragile, heavy, or several items | A cardboard box | Rigid, stackable, protects on all sides |
| Clothing or other soft goods | A grey mailing bag | Light, quick to pack, keeps size down |
| A small, hard or sharp-cornered item | A Jiffy padded bag | Padding resists punctures, no filler needed |
Tip for small shops
Check the postal size before you choose. Royal Mail prices by size as well as weight: a Large Letter can be up to 35.3 x 25 x 2.5 cm and 750 g (Royal Mail size guide). A flat mailer that keeps an order inside that limit costs less to post than a box.
Ready to order packaging featured in this guide?
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Related Technical Guides
Single vs Double Wall Boxes: How to Choose
How to Ship Clothes: Mailing Bags and Grip Seal Bags
Royal Mail Sizes: Mailing Bags vs Padded Envelopes
