The most common mistake on a bedding box is sizing it from the sheet. A queen flat sheet is enormous and completely irrelevant to the carton, because what goes in the box is a folded, compressed stack that has almost nothing to do with the unfolded textile. Fold one, squash it, measure that.
The mattress sizes behind the product
Useful as context for which SKUs you are packing, and nothing more. These are the published US mattress dimensions the bedding itself is cut to.
| Size | Mattress (in) |
|---|---|
| Twin | 39 x 75 |
| Twin XL | 39 x 80 |
| Full | 54 x 75 |
| Queen | 60 x 80 |
| King | 76 x 80 |
| California King | 72 x 84 |
Two sets at the same mattress size can fold to very different stacks. Thread count, weave, fibre and whether the set includes a duvet cover change the bulk far more than the size label does.
Getting the stack dimension right
- Fold a complete set exactly as your packing station will fold it, including the pillowcases and any insert card.
- Compress it with the pressure a person actually applies. Do not measure a loose stack, and do not assume vacuum compression unless you are buying it.
- Measure length, width and height of the compressed stack.
- Add roughly a quarter inch per dimension so the box fills quickly at the bench. A carton that needs two hands and a shove costs you labour on every unit.
- Write the result as internal length x width x depth, and ask for confirmation on the quote that the figure is internal.
Test the heaviest and loftiest SKU you sell, not the average one. It is cheaper to have a slightly generous box across the range than two tooling runs.
Construction choices that matter for bedding
- Window or no window. Bedding sells on hand feel, and a window that exposes a corner of the fabric does real work on a shelf. It also adds a film layer, which complicates the recycling story, so pick one priority.
- Handles. A queen set is heavy and awkward. A die-cut handle or a reinforced ribbon handle turns it into a carry-home purchase.
- Reclosable lid. Bedding boxes get reused for storage, and a lid that closes again after opening keeps the box, and the brand on it, in the house.
- Board. Folding carton is fine for a retail set. If the box is also the shipper, it needs corrugated, because a heavy textile stack will bow a carton wall over a long transit.
Ordering and turnaround
Minimum order is 100 boxes and pricing starts from about $0.48 per unit at bulk volumes, confirmed on your written quote. The die, the plates, design support, US shipping and a digital proof before anything prints are included, so an internal size matched to your exact folded stack costs no more to tool than a rounded one. We make in two plants, West Chicago in the US and Guangzhou in China. Turnaround is quoted per product in three lanes: rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days plus 2 to 5 for delivery. Rush adds about 7 to 25% depending on the job.
Order the product at bed sheet packaging. If the retail box will also travel as an ecommerce parcel, check the arithmetic on dimensional weight first, because bedding is light for its volume and carriers bill it on size.
Send the compressed stack measurement and your SKU range through the quote form and we will come back with an internal dimension, a board spec and a written price.
