Custom Mailer Boxes: 3 Ply vs 5 Ply Corrugated – Which Saves 20% on Shipping for E-commerce?
Let’s cut to the chase: E-commerce sellers lose money on shipping because they pick the wrong corrugated boxes. You either grab 5 Ply (too heavy, pricey to ship) or 3 Ply (worried it’ll break) and end up overspending. But here’s the secret: One of these saves 20% on shipping without sacrificing protection—and it’s not the one you might think.
This guide breaks down 3 Ply vs 5 Ply Custom Mailer Boxes, so you can stop guessing and start saving.
First: What’s the Difference Between 3 Ply and 5 Ply?
It’s all about layers (and weight—key for shipping costs):
3 Ply Corrugated: 3 layers total—1 outer paper, 1 wavy “flute” core, 1 inner paper. Light, flexible, and perfect for most small-to-medium items.
5 Ply Corrugated: 5 layers—2 outer papers, 2 flute cores, 1 middle paper. Thicker, heavier, and built for heavy or fragile stuff.
The biggest gap? Weight. A standard 10x8x4-inch 3 Ply box weighs ~0.3 lbs; the same size 5 Ply weighs ~0.5 lbs. That extra 0.2 lbs per box adds up fast in shipping fees.
Which Saves 20% on Shipping? (Spoiler: It’s 3 Ply)
Here’s the math from a client who sells women’s dresses:
- They used 5 Ply Custom Mailer Boxes (0.5 lbs each) for 500 monthly orders. Shipping cost ~$5.00 per box (USPS Priority).
- Switched to 3 Ply (0.3 lbs each). Shipping dropped to ~$4.00 per box.
- Monthly savings: $500. That’s 20% off shipping—exactly.
Why? Carriers charge by “dimensional weight + actual weight.” 3 Ply’s lighter weight slashes that cost. And no, it didn’t break more boxes: Their return rate stayed at 2% because 3 Ply still protects folded dresses, scarves, or small accessories.
5 Ply only makes sense if your product needs the extra heft. A client selling ceramic mugs tried 3 Ply first—8% of mugs broke. Switched to 5 Ply, breakage hit 1%, and even with higher shipping, they saved money on replacements.
- When to Pick 3 Ply (and When to Stick to 5 Ply)
Don’t just chase shipping savings—match the box to your product:
Pick 3 Ply If You Sell:
Light, soft items: Folded clothes, socks, jewelry, or small gadgets (phone cases, headphones).
Items that don’t crush easily: Think t-shirts, swimwear, or fabric accessories.
Bonus: 3 Ply is thinner, so you can print crisp logos and designs for Branded Mailer Boxes—no bulky layers messing up your brand look. A startup swimwear brand used 3 Ply Branded Mailer Boxes and got 15% more social shares (customers loved the sleek design).
Pick 5 Ply If You Sell:
Heavy items: Bulk apparel (3+ hoodies), small electronics (tablets, speakers), or tools.
Fragile items: Glass jars (candles, skincare), ceramic goods, or framed art.
Pro tip: Even 5 Ply can be Branded Mailer Boxes—just opt for a slightly larger size to fit your design without crowding the thick layers.
4：Final Tip: Don’t Skip Branding (Even for Budget Boxes)
Here’s what most sellers miss: Saving on shipping doesn’t mean ditching Branded Mailer Boxes. Both 3 Ply and 5 Ply Custom Mailer Boxes can have your logo, color, or a quick “Thank You” note— and it’s worth it. A client selling pet accessories used 3 Ply Branded Mailer Boxes, and 12% of customers mentioned the box in reviews (“Love the cute logo!”)—boosting repeat buys.
Wrapping Up
For 80% of e-commerce sellers (think clothing, accessories, small goods), 3 Ply Custom Mailer Boxes are the sweet spot: They save 20% on shipping, protect your products, and work great for Branded Mailer Boxes. If you sell heavy or fragile items, 5 Ply is non-negotiable—but you’ll still save vs. using generic “one-size-fits-all” boxes.
The takeaway? Stop overpaying for 5 Ply when you don’t need it. Test 3 Ply first—you’ll likely be surprised how much it saves.
Need Expert Guidance?
ANG specializes in custom packaging for global fashion brands. Contact us for a free consultation material and sample.
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