Box size/Insurance for shipping large quantity to retailers

We also purchase boxes and bubble wrap from Uline. They ship from locations all over the US, have an extensive catalogue and its very quick and easy to order from them.

Most of our shipping is of embroidered polos which are folded using a flip fold so our box sizes are based on the folded size of the shirts in one or two stacks depending on the size of the box (one stack for the two smaller boxes and two stacks for the two larger sizes. We also use vendor boxes which are usually wider than our folded stacks but we either take up the space with vertically stacked shirts or bubble wrap. With large quantities of screen printed shirts I would screen printer's fold them so I would probably choose a box size that would neatly accomodate a single pile of folded XL T's but if you have a whole box with one size you might purchase 2-3 sizes to accomodate different shirt sizes. I would also consider what my average order size was and what size boxes are easy for me to handle.

Uline does carry some variable size boxes (can be easily cut down to a smaller size) and they do run sales and offer better pricing on some popular sizes.

Although it is generally cheaper to ship fewer boxes you can incur additional costs by shipping extra large/heavy boxes. We use UPS Ground and I know they have some restrictions. I'm thinking that for pickup there is an additional cost for boxes exceeding 60lbs but I would have to check on that to be certain.