postage boxes

For any UK seller posting products, postage boxes are the rigid cardboard boxes sized to Royal Mail formats that protect an order in transit and keep it in the lowest postage band its size allows. Custom Postal Boxes manufactures plain and custom printed postage boxes in Wolverhampton with low minimum order quantities, free design support and free UK delivery on quoted orders.

Choosing postage boxes by Royal Mail format

Royal Mail prices post by size as well as weight. A letter can measure up to 240 mm by 165 mm by 5 mm and weigh up to 100 g. A large letter can reach 353 mm by 250 mm by 25 mm and 750 g. A small parcel can reach 450 mm by 350 mm by 160 mm and 2 kg, and a medium parcel 610 mm by 460 mm by 460 mm and 20 kg. The Royal Mail tracked services page lists these formats with tracked services.

That is why format led ranges exist. Our Letterbox Postal Boxes and Large Letter Postal Boxes are built for the large letter band, while Small Postage Boxes suit typical small parcel orders. Choosing by format first, and by product second, prevents the common mistake of a box that is slightly too deep for the band you intended.

Board strength for everyday posting

Most daily orders travel well in single wall corrugated board, which balances protection, weight and storage space. Step up in grade when the product is heavy for its size, fragile or valuable, or when parcels are stacked in cages for long routes. Board that is stronger than needed adds weight to every parcel, so match the grade to the product rather than defaulting to the thickest board for everything you sell.

Why a snug box protects better than a big box

A product that can move will eventually strike a wall of the box with force. A snug box limits that movement, needs less void fill and presents better on arrival. Measure your product as it will be packed, including any bottle cap, lid or folded sleeve, and allow only a small margin. Sellers with several product sizes usually settle on two or three box sizes that cover most orders well.

Plain or printed postage boxes

Plain boxes suit mixed product ranges, marketplace selling and packing benches where speed matters most. Printed boxes carry your logo and colours through the delivery network and onto the doorstep, which helps independent brands look established and encourages repeat orders. Many sellers print one hero size for their best selling line and keep plain boxes for the rest, which controls cost while still branding most parcels that leave the building.

The full Postal Boxes by Size category groups our sized ranges in one place, and Printed Postal Boxes shows the custom print route. Both are made in house, so a plain stock size and a printed version of the same footprint can be run together for a consistent packing process.

Packing and ordering postage boxes

Pack with the heaviest item at the base, wrap anything fragile, fill remaining voids lightly and seal the lid or flaps fully. Weigh and measure one finished parcel of each type you send and keep those figures at the packing bench, so staff can choose the right service without guessing. A box that arrives intact and on the expected service is the cheapest marketing most small sellers ever buy.

Order by sharing your sizes and quantities through our contact page for a quote. Pricing depends on size, material and quantity, and no fixed prices are listed because specifications vary so widely. Every quoted order includes free design support where print is needed and free delivery across the UK.

FAQs about postage boxes

What size postage box do I need for my product?

Measure your product as it will be packed, then choose the smallest box that holds it with a small margin and keeps the parcel in your intended Royal Mail format. Check depth carefully, because depth most often pushes a pack from large letter into small parcel. A trial pack settles the question before you order in quantity.

What is the difference between postal boxes and postage boxes?

In everyday UK use the two terms describe the same rigid cardboard boxes for sending products by post and courier. Buyers search both phrases, and suppliers list both. What matters is the size, board grade and format, not the word on the listing, so compare those details when you choose.

Can postage boxes be custom printed with my branding?

Yes. Postage boxes can be printed with your logo, colours and messages on the outside, the inside or both. Custom Postal Boxes offers free design support and low minimum order quantities, so printed boxes are practical for growing brands as well as established sellers with regular daily volumes.

How many postage box sizes should a small seller keep?

Most small sellers manage well with two or three sizes covering their smallest, typical and largest orders. More sizes than that can slow packing and complicate storage. Review your recent orders, group them by size, and choose boxes for the groups you send most often rather than for rare exceptions.