How Much Does E-commerce Packaging Cost? Per-Order Pricing for DTC Brands (2026)
E-commerce Packaging Costs: Package + Ship, Together
DTC founders obsess over CAC (customer acquisition cost) and forget about CPO (cost per order). Your packaging and shipping combined is often 15-25% of your AOV. Optimize here and your bottom line improves on every single order.
Here's what everything actually costs, from the box to the tape to the tissue paper to the carrier.
Packaging Component Pricing
| Component | 500 units | 1,000 units | 5,000 units | 10,000+ units |
|---|---|---|---|---|
| Mailer box (small, 8×6×3") | $2.80 | $1.90 | $1.20 | $0.95 |
| Mailer box (medium, 12×10×4") | $4.20 | $3.00 | $2.00 | $1.55 |
| Mailer box (large, 16×12×6") | $5.80 | $4.20 | $2.90 | $2.20 |
| Interior printing (add to mailer) | +$0.40 | +$0.30 | +$0.20 | +$0.15 |
| Poly mailer (10×13") | $0.35 | $0.24 | $0.15 | $0.10 |
| Poly mailer (14.5×19") | $0.48 | $0.34 | $0.22 | $0.15 |
| Custom tissue paper (per sheet) | $0.18 | $0.12 | $0.08 | $0.06 |
| Branded stickers (2" circle) | $0.08 | $0.05 | $0.03 | $0.02 |
| Thank-you/insert card | $0.18 | $0.12 | $0.08 | $0.05 |
| Custom packing tape (per box) | $0.12 | $0.08 | $0.05 | $0.03 |
| Die-cut foam insert | $0.80 | $0.55 | $0.35 | $0.25 |
Total Unboxing Experience Costs by Tier
| Tier | Components | Cost (5K qty) |
|---|---|---|
| Basic | Kraft mailer box + sticker | $1.23/order |
| Branded | Printed mailer + tissue + sticker + card | $2.31/order |
| Premium | Printed mailer w/ interior + tissue + sticker + card + tape | $2.56/order |
| Luxury | Premium mailer + tissue + sticker + card + tape + foam insert | $2.91/order |
The jump from Basic to Premium is just $1.33 per order. For a brand shipping 5,000 orders/month, that's $6,650/month for an experience that drives social sharing and repeat purchases.
Total Cost Per Order: Packaging + Shipping
| Scenario | Packaging | Shipping (avg) | Total CPO | % of $50 AOV |
|---|---|---|---|---|
| Poly mailer (light item) | $0.18 | $4.20 | $4.38 | 8.8% |
| Small mailer, basic | $1.23 | $6.50 | $7.73 | 15.5% |
| Medium mailer, branded | $2.31 | $8.50 | $10.81 | 21.6% |
| Medium mailer, premium | $2.56 | $8.50 | $11.06 | 22.1% |
| Large box, heavy product | $3.25 | $12.00 | $15.25 | 30.5% |
Four Ways to Cut DTC Packaging + Shipping Costs
- Right-size your box. A box 2" smaller in each dimension can drop one DIM weight bracket — saving $1.50-$3.00 per shipment. That's $15,000-$30,000/year at 10K orders/month.
- Use poly mailers for anything non-fragile. Clothing, accessories, books, cosmetics pouches — all ship safely in poly. Savings: $6-$10 per order vs. mailer boxes.
- Order quarterly at 5K+. Packaging cost drops 40-55% from 500 to 5,000 units. Plan ahead.
- Negotiate carrier rates at volume. Once you're shipping 500+ orders/month, UPS and FedEx discount 15-30% off published rates. Ask.
Frequently Asked Questions
What's the cheapest professional-looking DTC packaging?
Custom printed poly mailer ($0.15) + branded sticker ($0.03) = $0.18/order at 5K quantity. Looks branded, ships cheap, and works for apparel, accessories, and non-fragile products.
How much does interior printing cost?
$0.15-$0.40 per box depending on quantity. At 5K units, it's $0.20/box. Brands consistently report this is the single highest-ROI upgrade for social media engagement.
Should I invest in the full unboxing stack?
If your AOV is above $35 and you rely on repeat customers: yes. The premium unboxing tier costs $2.56/order and drives measurably higher repeat purchase rates and social sharing. Below $25 AOV, stick with the basic tier to protect margins.
Build your custom packaging stack. Get a quote with your exact product dimensions and monthly volume. We'll spec the right format at the right price. Or browse e-commerce packaging options.
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