large postage boxes

Large postage boxes are postal boxes sized for bulky products and multi item orders that will not fit a standard small parcel box, while still aiming to stay inside a sensible postage band. Custom Postal Boxes manufactures large postage boxes in Wolverhampton for UK businesses, with low minimum order quantities, free design support and free UK delivery on every order.

When large postage boxes are the right choice

You need a larger box when the product itself is bulky, when several items travel together or when protective packaging adds real depth. Homeware, boxed footwear, small appliances, gift hampers and clothing bundles all commonly need this size range. The Royal Mail medium parcel band allows up to 610mm by 460mm by 460mm and up to 20kg, which gives generous room, yet postage rises with weight steps inside that band. Choosing cardboard shipping boxes sized close to your typical order keeps you in control of both protection and postage spend across the year.

Matching box size to the medium parcel band

Work out the largest order you send regularly, pack it as a customer would receive it and measure all three external dimensions plus the total weight. If the packed parcel sits just over a weight step, lighter board or less filler may bring it back under. Check current limits and prices on the Royal Mail price guidance before fixing your box size, because a few millimetres or a few hundred grams can change what every single parcel costs to send.

Avoiding wasted space in a big box

A large box sent half empty wastes board, filler and postage, and lets contents shift and damage each other. If order sizes vary widely, consider two box sizes rather than one giant carton for everything, or use internal dividers so a smaller order sits securely in part of the space. Filler should cushion and separate, not simply fill air, so choose void fill with a purpose for each product type.

Board strength for large postage boxes

Bigger boxes flex more than small ones, so board choice matters more at this size. Single wall corrugated board suits lighter bulky goods such as bedding, clothing and soft toys. For heavier or denser orders, double wall shipping boxes resist bulging and stacking pressure far better, and heavy duty shipping boxes suit the top of the weight range. Tape the base fully, support long edges and keep the heaviest item at the bottom so the box travels square through sorting machinery and delivery vans.

Packing bulky orders so they arrive intact

Wrap items individually where surfaces can rub, place fragile pieces away from the corners and fill gaps so nothing can gather speed inside the box. A quick shake test at the bench tells you if more cushioning is needed, because a well packed parcel is quiet when lifted. Put the delivery label on the largest flat face, keep tape away from the label area and add a second address card inside the box in case the outer label is damaged in transit.

Ordering large postage boxes for regular dispatch

List your bulkiest regular orders, weigh them packed and decide whether one size or two sizes will cover the range sensibly. Pricing depends on size, material and quantity, and larger boxes use more board, so accurate sizes protect your margins as well as your products. Low minimums let you trial a size during a busy period before committing. The custom shipping boxes category shows related styles, or send your measurements through our contact page for a quote for advice on board grade and free design support.

FAQs about large postage boxes

What size is a large postage box for Royal Mail?

Large orders usually travel as Royal Mail medium parcels, which allow up to 610mm by 460mm by 460mm and up to 20kg. Your box should fit your packed order inside those limits with the tape and labels applied.

Should I choose single wall or double wall board?

Single wall board suits lighter bulky goods such as clothing and bedding. Double wall board is the safer choice for heavier, denser or fragile orders because it resists bulging, stacking pressure and knocks in transit.

How do I stop items moving inside a large box?

Wrap items where surfaces can rub, position heavy goods at the base and fill gaps with cushioning so nothing can slide. The packed box should feel firm and stay quiet when you lift and tilt it gently.

Can large postage boxes be printed with my branding?

Yes. Large postage boxes can carry your logo, colours and handling messages in print. Free design support is included, pricing depends on size, material and quantity, and UK delivery is free.