DIY Packaging: Which Materials for Which Products

Packaging is a margin game. Under-pack and items get damaged, eating profit in returns. Over-pack and you waste money and space. The sweet spot varies by product. Here's what to use for each common product category.

Bubble Wrap — The All-Purpose Protector

• Use for: fragile items (glass, ceramics, electronics, jewelry)
• Small bubble (3/16"): small delicate items
• Medium bubble (5/16"): most general use
• Large bubble (1/2"): heavy fragile items
• Wrap 2-3 layers around fragile items
• Bulk rolls from Uline, Amazon Business, PackagingBrahma

Kraft Paper — Eco + Cheap

• Use for: void fill, wrapping non-fragile items
• 30 lb weight: standard wrapping
• 50 lb weight: heavy-duty, reinforced
• Curbside recyclable (huge sustainability win)
• Cheaper per foot than bubble wrap for void fill
• Brands: Uline, Scotch, PackagingBrahma

Packing Peanuts — Void Fill

• Use for: filling empty space in boxes to prevent shifting
• EPS foam (traditional): cheapest, not recyclable
• Biodegradable starch: eco-friendly, dissolves in water
• Air pillows: cheapest per cubic inch, neat disposal
• Not a replacement for bubble wrap — peanuts don't protect fragile items

Corrugated Boxes — The Foundation

• Single-wall (standard): under 15 lb contents
• Double-wall: 15-30 lb contents, fragile items
• Triple-wall: 30-50 lb, heavy or fragile
• Match box size to contents (avoid DIM weight penalties)
• Bulk from Uline, Amazon Business

Poly Mailers — For Soft Goods

• Use for: clothing, soft accessories, flat items
• 2.5 mil: standard clothing
• 3+ mil: multi-item or heavier soft goods
• Cheaper per unit than boxes + lighter = DIM weight savings
• Not for fragile items (no protection)

Bubble Mailers — Hybrid Small Item Protection

• Use for: small fragile items (jewelry, small electronics, books)
• Kraft exterior + bubble lining
• Convenient peel-and-stick closure
• Cheaper than bubble-wrapping + boxing for individual small items

Tape — Don't Skimp Here

• Packing tape (polypropylene): standard clear packing tape
• Kraft paper tape: eco-friendly, curbside recyclable
• Reinforced paper tape: heavy boxes
• Don't use: masking tape, duct tape, cheap dollar-store tape (fails in transit)
• Apply using H-method: seal center + both side seams

Cheapest Per Product Category

• Clothing: Poly mailer + optional tissue paper
• Books: Bubble mailer or Media Mail-appropriate box
• Jewelry: Bubble mailer with jewelry box inside
• Electronics: Box with 2-3" bubble wrap padding
• Ceramics: Box-in-box, multiple layers bubble wrap
• Candles: Box with bubble wrap + insulation in summer
• Fragile art: Rigid mailer or box with corner protectors