Custom Pyjama Boxes

Folding and Sizing Pyjama Sets

The best way to size a pyjama box is to fold a set exactly as you want customers to see it. Most brands fold the top with the collar and front facing up and the trousers folded underneath, all wrapped in tissue. Measure that folded bundle for length, width and height, and add 5 to 10 mm on each side so the set goes in without being squashed.

Shorts sets and camisole sets fold smaller than full-length pyjamas, while brushed cotton and flannel sets are thicker than silk or satin. If you sell a range of fabrics and styles, two or three box depths with the same footprint will usually cover everything, which keeps your stock simple and your display uniform. Children's sets can often share a smaller box footprint.

Fabric behaviour matters when you fold. Silk and satin slide and crease if they are packed loosely, so a snug box and a sheet of tissue between the top and trousers keeps them smooth. Brushed cotton and fleece are springy and push against the lid, so give them a few extra millimetres of depth or the lid will sit proud. Fold a sample of each fabric you sell and leave it in a test box overnight; you will see quickly whether the size is right. Our guide to measuring folded garments covers tissue and depth allowances.

Custom Pyjama Boxes in Rigid or Folding Board

Rigid boxes are made from thick greyboard wrapped in printed or coloured paper. They feel solid and luxurious, keep their shape when stacked and are often reused for storage. They arrive made up, so they need shelf space in your workroom. Folding boxes are made from lighter board that arrives flat and folds into shape. They are lighter to post, take less storage and still look smart, especially with a good finish.

Many sleepwear brands choose rigid boxes for their premium lines and gift sets, and folding boxes for everyday sets sold online. Using the same colours and logo on both keeps the brand consistent. Shirts from the same brand go in the slimmer shirt boxes with a collar support in the same wrap.

Colours, Patterns and Finishes

Sleepwear packaging tends to feel calm and cosy. Soft neutrals, pastels, deep navy and forest green are popular, as are patterns taken from your fabrics, such as stripes, florals or stars. A pattern repeated on the lid, with a plain base, looks considered without being busy. Printing inside the lid with a short line about rest or comfort makes a nice moment when the box is opened.

A matt or soft-touch finish suits the feel of sleepwear and makes the box pleasant to hold. Foil stamping on the logo adds a gift-worthy shine, and embossing can add texture to a monogram. A ribbon tied around the box or a belly band printed with the set name adds a final touch for gift orders. The board and finish comparison page shows soft-touch next to matt on a printed lid.

Tissue, Cards and Inserts

Inside the box, branded tissue paper wraps the set and protects it from dust and handling. A sticker seals the tissue. A small card can carry care instructions, sizing information or a gift message, and some brands add a matching eye mask or scrunchie as a small extra. A card insert with a slot can hold these extras neatly so they do not slide under the set.

If the box is going into the post, it needs to sit inside an outer mailer or be a sturdy mailer box itself. We can size the outer to fit the pyjama box closely so it does not move in transit.

Fold a Set, Wrap It, and Leave It Overnight

The only reliable way to size a pyjama box is to fold a real set the way customers will see it, wrap it in tissue and measure the bundle, then leave it in a test box overnight. Flannel springs back and pushes the lid proud; silk settles and slides. That test shows if the 70 mm or 90 mm depth is right. Keep one footprint across the range and vary only the depth, so adult, shorts and children's sets look like one collection on the shelf.

Send the folded sizes for each fabric, the style you prefer, rigid or folding, and the finish, and a custom quote comes back by email within one working day with minimums quoted per job. The free proof shows the lid, base and any inside print. Production takes 4–7 working days after approval and tracked delivery to UK mainland addresses is free, taking 2–3 working days; rigid boxes arrive built, folding ones flat. Boxes that arrive misprinted or damaged are reprinted or refunded when reported within 10 days. Robes sold with the set usually need the deeper blanket boxes for bulky textiles.