postage packaging boxes

postage packaging boxes are boxes chosen to protect goods in the post while keeping the packed size and weight inside the right Royal Mail band. Custom Postal Boxes supplies printed and plain postage packaging boxes from Wolverhampton, made in house with free design support, low minimum order quantities and free UK delivery.

Sizing postage packaging boxes to Royal Mail bands

Royal Mail charges by size as well as weight, so postage packaging boxes should be planned around the packed dimensions. A large letter can measure up to 353 mm by 250 mm by 25 mm and weigh up to 750 g. A small parcel can measure up to 450 mm by 350 mm by 160 mm and weigh up to 2 kg, and a medium parcel up to 610 mm by 460 mm by 460 mm and up to 20 kg. A box even slightly over a band limit moves the whole order into a higher charge, so close fitting boxes save money on every parcel. Our large letter postal boxes and small postage boxes show the two most used bands.

Choosing board strength for the journey

Single wall corrugated board suits light, robust goods and keeps the pack weight down. Double wall board suits heavier, fragile or stacked loads, and kraft board is a popular outer for a natural brand look. Match the board to the product weight and the journey rather than buying the thickest board for everything, because excess board adds weight and cost to each parcel. Compare single wall corrugated boxes with cardboard postal boxes for everyday posting.

Filling voids and sealing well

Goods should not slide inside the box. Fill voids with paper or other suitable cushioning, keep fragile items away from the box walls and seal every opening with strong tape. Royal Mail gives the same advice for heavy parcels, including reinforcing the base and weighing the finished pack, in its guidance on packaging heavy items.

Print, storage and repeat ordering

Printed postage boxes carry your logo and handling guidance on the outside and a message inside the lid, turning a delivery into a brand contact. Most postage boxes store flat, so a mixed set of two or three sizes can cover most orders without filling your packing area. Keep a packed sample of your best selling product in each size to train packers and to check postage bands after any product change. Pricing depends on size, material and quantity, so request a quote with your product sizes, weights and monthly volumes, and ask about print on our A5 postal boxes and other core sizes.

FAQs about postage packaging boxes

What size box keeps a parcel in the Royal Mail large letter band?

The packed item, including the box and any padding, must stay within 353 mm by 250 mm by 25 mm and weigh no more than 750 g. Measure the finished pack rather than the empty box, because tape, labels and cushioning all add a little size and weight.

Should I choose single wall or double wall board?

Choose single wall for light and robust goods where keeping pack weight low matters. Choose double wall for heavier, fragile or valuable goods and for parcels that may be stacked in transit. Match the board to the load rather than using one grade for every order.

How do I stop goods moving inside a postage box?

Pick the closest box size first, then fill any remaining void with suitable cushioning so the contents cannot slide. Keep fragile items away from the walls, close the flaps without forcing them and seal all openings with strong tape.

Can postage boxes be printed with my logo?

Yes. Lids and side panels can carry your logo, colours and handling messages, and the inside of the lid can carry a thank you or reorder message. Free design support helps you place artwork so it avoids folds and locking areas.

How many sizes should a small shop stock?

Two or three well chosen sizes cover most small shops. Start with the size that fits your best selling product, add a large letter size if you sell slim items and a larger parcel size for sets or multi item orders.