Custom Small Parcel Boxes UK

Send compact products in postal packaging designed around their dimensions, weight and delivery journey. All Custom Packaging produces custom small parcel boxes for online retailers, marketplace sellers, subscription businesses and independent brands across the UK.

A stock box that nearly fits can still add unnecessary length, width or depth to every order. Custom sizing allows the box to fit the packed product more closely while staying within the relevant carrier limits where the item dimensions and weight permit.

Orders start from 100 units per design, with no setup fees, free design support and a free 3D mockup. Once the design and physical sample have been approved, production normally takes 6 to 8 business days, followed by free delivery throughout the UK.

Why Online Sellers Choose All Custom Packaging

Small-parcel delivery charges are based on the finished parcel, not the unboxed product. The external box dimensions, packed weight and selected service determine which postal or courier category applies.

An oversized carton can:

• Move the parcel into a higher delivery category
• Require more void-filling material
• Allow the product to move during handling
• Occupy unnecessary storage space
• Create a less considered unboxing experience

We develop the box around the complete packed arrangement, including the product, retail packaging, inserts, wrapping and accessories.

Our service includes:

• Bespoke external and internal dimensions
• Single- or double-wall corrugated board
• Full-colour or simple branded printing
• Product-specific inserts and dividers
• Carrier-band planning
• Free packaging design support
• Free 3D mockup
• Physical sample video approval
• Free delivery anywhere in the UK

Before the complete production run, you can review the physical sample on video and check the product fit, external dimensions, board, closure and printed presentation.

Small Parcel Box Formats We Make

Our PiP Small Parcel Boxes and Small Parcel Postal Boxes are developed for businesses sending products through size-based postal services.

For Royal Mail, a Small Parcel must currently remain within maximum external dimensions of 450 × 350 × 160 mm and a maximum weight of 2 kg. The packed parcel, including any bulging panels or overfilled flaps, must remain within those limits. Other carriers use their own dimensional and weight rules, so the intended service should always be confirmed before production.

PiP-style boxes can be used for:

• Jewellery and accessories
• Skincare and cosmetics
• Clothing items
• Books and stationery
• Small homeware
• Gifts
• Replacement parts
• Subscription products
• Marketplace orders

The box can be cut below the maximum size rather than automatically using the largest permitted dimensions.

Printed Small Parcel Boxes

Our Small Parcel Boxes UK and Small Parcel Delivery Box formats combine postal-friendly sizing with custom branding.

Printing can include:

• Business logos
• Brand colours
• Product or collection names
• Social media details
• Website information
• Reorder QR codes
• Handling guidance
• Return instructions
• Thank-you messages
• Disposal information

The exterior can introduce your brand when the parcel arrives, while internal printing can continue the presentation when the customer opens the box.

Double-Wall Small Parcel Boxes

Our Double Wall Small Parcel Boxes provide additional compression and puncture resistance for heavier, fragile or more demanding small-parcel shipments.

Double-wall board contains two fluted layers and may be suitable for:

• Glass containers
• Several products packed together
• Dense or heavy items
• Fragile accessories
• Products exposed to stacking
• Longer delivery journeys

Double wall is not automatically necessary for every small parcel. It uses more material and weighs more than a suitable single-wall box.

Where the product dimensions allow, double-wall construction can be developed while keeping the finished external box inside the required carrier dimensions. The thicker board reduces the available internal space, so the product fit must be checked on the sample.

Small Cosmetic Parcel Boxes

Our Small Cosmetic Parcel Boxes can be designed for skincare, makeup, fragrance and personal-care orders.

These boxes can hold products such as:

• Serum and dropper bottles
• Cream jars
• Lipsticks and lip balms
• Mascara
• Small fragrance products
• Cosmetic gift sets
• Beauty subscription items

Glass bottles and jars may require fitted inserts or corrugated dividers. The box dimensions should include the retail cartons, wrapping and any additional product protection.

The exterior and interior can be coordinated with your wider cosmetic packaging range.

Small Food Parcel Boxes

Our Small Food Parcel Boxes can be created for suitable packaged bakery products, confectionery, biscuits and other food products sold online.

The complete packaging arrangement should consider:

• Product weight
• Primary food wrapping
• Movement during delivery
• Moisture or grease
• Required inserts
• Courier journey
• Food-contact conditions

The outer postal box does not replace suitable primary food packaging. Where food directly touches an internal material, the relevant food-contact specification must be confirmed.

Coloured Small Parcel Boxes

Our Pink Small Parcel Boxes provide a ready-coloured presentation for brands that use a distinctive colour across their packaging.

Coloured boards can be combined with:

• A simple printed logo
• White or contrasting ink
• Branded labels
• Inside-lid messages
• Tissue paper
• Product stickers

A pre-coloured surface can create a strong presentation without applying full-colour artwork across every panel.

Blank and Empty Parcel Boxes

Our Blank Small Parcel Boxes and Empty Small Parcel Boxes provide an unprinted option for businesses that prefer simple postal packaging.

Plain boxes can be completed with:

• Branded stickers
• Printed packing tape
• Shipping labels
• Product sleeves
• Stamps
• Tissue paper
• Handwritten messages

This approach may suit businesses with frequently changing products or several brands using the same box size.

Wholesale Small Parcel Boxes

Our Small Parcel Boxes Wholesale range supports businesses sending higher volumes of products in consistent packaging.

Ordering larger quantities of the same box design can improve unit efficiency and help maintain a reliable supply for regular fulfilment.

Before ordering wholesale volumes, the sample should confirm:

• Product fit
• Packed dimensions
• Board strength
• Assembly method
• Closure
• Printing
• Carrier category

Sizing the Box to the Delivery Band

Point	Why It Matters
Carriers measure the packed parcel	The external dimensions and final weight determine the available service and price category
Custom sizing controls empty space	A closer fit can reduce movement, unnecessary board and void-filling material
Every dimension matters	Exceeding a limit in length, width or depth can move the parcel into another category
Packed weight must be included	A dimensionally suitable box can still exceed the service’s weight allowance
Current limits must be checked	Postal and courier specifications can change, and each carrier uses its own rules
Board thickness affects internal space	Double-wall construction can strengthen the parcel but reduces the usable dimensions inside

Tell us what you are sending, its complete packed measurements and the carrier you intend to use. We can develop the external box dimensions around the current service limits where the product permits.

Measuring for a Small Parcel Box

Provide the dimensions of the complete packed product rather than only the bare item.

Measurements should include:

• Retail packaging
• Protective wrapping
• Inserts
• Dividers
• Product accessories
• Instructions or leaflets
• Tissue paper
• Any inner containers

Measure the maximum:

1. Length
2. Width
3. Height
4. Packed weight

Soft products should be measured after they have been folded or wrapped as they will be shipped. Do not assume that a flexible item will remain compressed unless the packaging keeps it securely in that form.

A small allowance may be needed for comfortable packing, but excessive clearance can allow the contents to move.

Royal Mail Small Parcel Dimensions

Royal Mail currently defines its Small Parcel format as:

• Maximum length: 450 mm
• Maximum width: 350 mm
• Maximum depth: 160 mm
• Maximum weight: 2 kg

These are maximum external parcel dimensions, not recommended box dimensions for every product. A box should normally be made as compact as practical for its contents.

Large Letter dimensions are smaller, particularly the depth limit, so a product close to that category should be measured carefully before deciding between a Large Letter and Small Parcel format.

Planning for Other UK Couriers

Courier services do not all use the same parcel categories as Royal Mail. Some price according to weight, dimensions, parcel volume, service type or a combination of these factors.

When requesting custom boxes, share:

• Carrier name
• Selected service
• Maximum permitted dimensions
• Maximum packed weight
• Any locker or drop-off restrictions
• Whether a dimensional-weight calculation applies

We will use the specifications supplied or current at the time of your order. The business sending the parcel should still confirm the final packed box against the carrier’s live rules before despatch.

Single-Wall or Double-Wall Board?

Single-Wall Corrugated Board

Single-wall board contains one fluted layer between two flat liners.

It is suitable for many everyday small parcels containing:

• Clothing
• Accessories
• Books
• Stationery
• Soft goods
• Lightweight cosmetics
• Non-fragile retail products

It provides useful shipping strength without adding the weight of an unnecessary second fluted layer.

Double-Wall Corrugated Board

Double-wall board contains two fluted layers and provides greater resistance to stacking, punctures and crushing.

It may be recommended for:

• Heavy products
• Fragile contents
• Glass containers
• Multi-item parcels
• Dense components
• Parcels exposed to more demanding handling

The decision should be based on the packed weight, box size, fragility and journey rather than choosing the thickest board automatically.

Inserts and Internal Protection

A strong outer box cannot protect a product properly when the contents move freely inside it.

Internal options can include:

• Corrugated dividers
• Die-cut card inserts
• End supports
• Product trays
• Layer pads
• Paper-based cushioning
• Bottle compartments
• Corner protection

The insert can hold the product away from the outer walls and help prevent several items from colliding.

For compact parcels, the insert should provide the required protection without adding enough height or width to move the parcel outside the intended delivery category.

Closures and Assembly

Small parcel boxes can use different structures depending on the product and packing process.

Available options can include:

• Tuck-top mailer closures
• Tab-lock sides
• Standard taped shipping cartons
• Self-seal adhesive strips
• Tear strips for opening
• Reinforced closing flaps

Fold-and-lock postal boxes are normally supplied flat and assembled when required, reducing the storage space occupied by empty packaging.

Self-seal strips can speed up repetitive packing, while taped cartons may be more suitable for heavier contents or demanding delivery journeys.

Printing Inside and Outside

Small parcel boxes can be printed in one, two or full colour.

One- or Two-Colour Kraft Printing

A simple logo or message on brown kraft board creates a clear branded-transit appearance at a controlled cost.

Full-Colour Exterior Printing

Full CMYK artwork can include detailed branding, illustrations, patterns and campaign designs.

Interior Printing

Inside printing can be used for:

• Thank-you messages
• Product instructions
• Subscription information
• Discount codes
• Return guidance
• Reorder QR codes
• Branded patterns

When the postal box is also the main customer-facing packaging, interior printing can create a more complete unboxing experience without adding another box.

Small Parcel Boxes for Marketplace Sellers

Custom parcel boxes are suitable for businesses selling through:

• Online marketplaces
• Independent webshops
• Social-commerce platforms
• Subscription services
• Craft and handmade stores
• Social media
• Direct-to-consumer websites

Marketplace sellers often ship a wide variety of products. Several carefully selected box sizes may be more efficient than using one oversized format for every order.

A small range might include:

• A compact box for single items
• A medium format for multi-product orders
• A stronger option for fragile goods

This makes it easier for packing staff to select a suitable box without creating unnecessary complexity.

Mailer, Parcel or Shipping Box?

Small Parcel Boxes

Choose small parcel boxes when:

• The packed item fits a carrier’s small-parcel category
• Postal dimensions are a priority
• The parcel contains compact products
• A lightweight corrugated format provides sufficient protection

Custom Mailer Boxes

Choose Custom Mailer Boxes when:

• The unboxing experience is important
• You need extensive inside and outside printing
• The product is suitable for a fold-and-lock structure
• The box is customer-facing as well as postal

Custom Shipping Boxes

Choose Custom Shipping Boxes when:

• Products are larger or heavier
• Several items are shipped together
• Strong taped closures are required
• Freight, wholesale or warehouse handling is involved
• More substantial internal protection is needed

The best format is the one that meets the product and carrier requirements without unnecessary weight or material.

Recycling and Material Choices

Selected corrugated small parcel boxes may be recyclable when clean, dry and accepted by the customer’s local collection service.

The disposal route can be affected by:

• Laminations
• Adhesive strips
• Tear tapes
• Labels
• Plastic components
• Foam inserts
• Product contamination

Paper-based inserts and dividers can make material separation easier in some packaging designs. Clear disposal guidance can also be printed onto the box once the complete specification has been confirmed.

Avoid absolute environmental claims until every component of the finished packaging has been reviewed.

How Ordering Works

1. Send Your Product and Carrier Details

Provide the packed product dimensions, weight, required quantity and intended postal or courier service.

2. Review the Free 3D Mockup

Our designers prepare the structure and branded artwork, then send a free 3D mockup for review.

3. Approve the Physical Sample

A physical sample is produced, and you receive a video showing the product fit, external size, board, closure and printing.

4. Production

Production normally takes 6 to 8 business days after the final design and physical sample have been approved.

5. Free UK Delivery

Completed small parcel boxes are delivered free of charge throughout the United Kingdom.

Order Custom Small Parcel Boxes

To request an accurate quotation, provide:

• Product dimensions
• Complete packed dimensions
• Final packed weight
• Required quantity
• Chosen carrier and service
• Preferred box format
• Single- or double-wall preference
• Insert or divider requirements
• Exterior and interior print requirements
• Artwork and brand-colour references

Our team will review the details and recommend a box size and board specification suited to the product and intended delivery category.

Frequently Asked Questions

What is a Small Parcel box?

A Small Parcel box is a postal carton designed for products that fit within the size and weight limits of a carrier’s small-parcel service.

What are Royal Mail’s Small Parcel limits?

Royal Mail currently permits a maximum size of 450 × 350 × 160 mm and a maximum packed weight of 2 kg. The finished external parcel must remain within every limit.

Can you make a box to fit inside the Royal Mail Small Parcel band?

Yes, where the product and required protection fit within the permitted dimensions and weight. Share the complete packed product measurements when requesting a quotation.

Is the largest permitted Small Parcel box always the best choice?

No. The box should be made as close to the required product size as practical. Using the maximum dimensions for a small item can create movement and require unnecessary filling material.

Can small parcel boxes be made for other couriers?

Yes. Provide the carrier and service limits, and the box can be developed around those dimensions where the product allows.

Should I choose single-wall or double-wall board?

Single wall suits many everyday parcels. Double wall may be recommended for heavier, fragile or stacked products. The correct choice depends on the packed weight and delivery conditions.

Can double-wall boxes still qualify as Small Parcels?

They can where the finished external dimensions and packed weight remain within the relevant carrier limits. Thicker board reduces the amount of internal space available.

Can inserts be added without making the box too large?

Yes. Inserts can be developed around the product and postal limit, although the available space must be considered carefully.

Are printed small parcel boxes available?

Yes. Boxes can include simple one-colour branding or full-colour printing on the exterior and suitable internal panels.

Are parcel boxes supplied flat?

Most fold-and-lock and corrugated postal boxes are supplied flat for efficient storage and assembled when required.

Can I order plain boxes?

Yes. Blank and empty small parcel boxes can be produced without custom artwork and completed with labels, tape or stickers.

Can I review the box before full production?

Yes. You receive a free 3D mockup and can approve a video of the physical sample before the complete run begins.

How long does production take?

Production normally takes 6 to 8 business days after the final design and sample have been approved.

Is UK delivery free?

Yes. Completed custom small parcel-box orders include free delivery throughout the United Kingdom.