Guide to Designing Packaging for Reverse Logistics & Returns

Why Design Packaging for Returns?

E-commerce returns are an immense and growing challenge – both logistically and environmentally. According to a study by Invesp, roughly 30% of all e-commerce purchases are returned, especially in apparel, and shoppers reward brands that make returns easy (92% say they’d buy again from a retailer if the return process is hassle-free). Designing packaging with reverse logistics in mind can turn this challenge into an opportunity. When your packaging is return-friendly – meaning it’s easy for customers to repack items and send them back – you not only reduce waste, you also improve customer loyalty and satisfaction. 51% of Gen Z consumers buy multiple products with the intention of returning some of them.

From a sustainability standpoint, the traditional “ship one way and trash the packaging” model is not always the best choice, whereas reusable and returnable packaging offers a powerful alternative. For EcoPackables and its clients, this means rethinking mailers and shipping bags to serve double duty: first getting products to customers safely, then facilitating an easy journey back if needed. In the guide below, we’ll explore key strategies – from multiple adhesive strips for resealing to durable reusable mailers – that make packaging return-ready.  In short, return-conscious packaging is good for the planet and for business.

Designing Packaging for Reverse Logistics: Key Strategies

Making packaging “reverse-logistics ready” comes down to smart design features and material choices that simplify the return process. Here are some core strategies to consider:

Use Durable, Round-Trip-Ready Materials:

Choose packaging that can withstand a round trip. Parcels often travel through multiple trucks and fulfillment centers twice (outbound and return), so a sturdy material can mean the difference between a successful return and a damaged product. For example, EcoPackables’ mailers use resilient materials (like recycled poly and  recycled paper) that hold up when reused. Durable construction ensures your package can make it to the customer and back again without tearing or falling apart.

Incorporate Perforated Tear Strips:

One common frustration for customers is destroying a package to open it, then having nothing intact to ship the return. A simple fix is adding a perforated tear strip on boxes or mailers for easy opening. This feature lets the recipient open the package cleanly without ripping the mailer or cutting through layers of tape. The intact packaging can then be reused for the return trip. Tear strips not only improve unboxing experience but also minimize damage to the package and encourage customers to reuse it for returns.

Dual Adhesive Strips for Resealing:

Perhaps the most game-changing feature for returnable packaging is the dual peel-and-seal strip. With a second adhesive strip built in, customers can reseal the same mailer to ship the product back. Many major retailers use this design – if you’ve ever noticed an Amazon poly mailer with two seal strips, that’s exactly how it works. The first strip is used by the seller to seal the package outbound; a second strip (under another peel-away liner) is left for the customer to seal the package for return. This eliminates the need for extra packaging or tape during return. EcoPackables recognizes the value of this approach – in fact, on our custom packaging we offer the option of one or two adhesive strips specifically to enable easy returns or reuse.

Include Return Labels or Mailers When Appropriate:

Depending on your business model, you might further simplify returns by providing a pre-addressed return label or even a spare mailer in the original shipment. For instance, some apparel styling services ship products in a box but include a folded poly mailer and return label inside for any items the customer sends back. Brands like MM LaFleur and thredUP do this to create a seamless return experience – the customer doesn’t have to hunt for a box or postage; everything needed for a return is on hand. While this means sending extra packaging, it ensures that even if the primary packaging isn’t reusable, the returns process is still frictionless. The decision to include an extra mailer should be weighed against your sustainability goals – often it’s used when the outbound packaging is a branded or rigid box not meant to be reused, so a supplemental eco-friendly mailer is provided for returns.

By implementing these design strategies – sturdy construction, easy-open features, dual reseal strips, and prepared return materials – you set your reverse logistics up for success. Now, let’s look at how EcoPackables’ specific packaging offerings put these principles into practice, and which types of businesses benefit most from each solution.

Mailer Types

Flat Mailers: Lightweight & Return-Ready for Apparel

Flat mailers are the slim, envelope-style shipping bags ideal for non-fragile items like clothing. They include unpadded poly mailers and paper mailers – all designed to be lightweight, cost-efficient, and space-saving for shipping. EcoPackables offers a variety of sustainable flat mailers, including the 100% Compostable PolyMailer and 100% Post-Consumer Recycled Kraft Mailers. These mailers are eco-friendly (made from compostable bio-materials or recycled paper) and built with e-commerce in mind. Crucially, our mailers can be customized with two adhesive closure strips – one for the initial shipment and a second for returns.


Flat mailers are especially well-suited for soft goods like clothing, accessories, and linens. Brands in fashion, boutique apparel, or subscription clothing boxes find flat mailers beneficial because they are slim (minimizing shipping costs) yet can expand enough to hold garments. For example, a styling service sending curated outfits might use a branded flat mailer with dual seals – the customer keeps what they like and sends back the rest in the same bag. By choosing a flat mailer material that aligns with your values (compostable vs. recycled plastic vs. recycled paper) you can also reinforce your sustainability messaging. EcoPackables’ flat mailers are customizable and can cover all these bases: earth-friendly materials, return-ready closure, and durability to survive multiple trips. For apparel companies, that means fewer discarded packages and a smoother return workflow for your fulfillment team.

Padded Mailers: Protective Packaging Made Reusable

When your products need extra protection in transit—like fragile items, electronics, or cosmetics—padded mailers are the go-to solution. EcoPackables offers sustainable options like 100% Recycled Honeycomb Paper Mailers and Compostable Bubble Mailers, which provide cushioning without plastic waste. These mailers can be designed with dual adhesive strips and a tear-open tab, making them both protective and return-friendly. Customers can open the mailer cleanly and reuse it for returns, preserving the padding and eliminating the need for new packaging.


Ideal for subscription boxes and e-commerce shipments, padded mailers protect delicate items like glass beauty products or small tech accessories. Reusing the same mailer for returns reduces costs and packaging waste. With both compostable and recycled versions available, EcoPackables' padded mailers support a range of sustainability goals—while maintaining durability for a return trip.

Reusable Fabric Mailers: Embracing Circularity in E-Commerce

Not all shipping bags have to be single-use. Reusable fabric mailers—made from materials like recycled polyester or canvas—are gaining traction with brands embracing circular economy models. Designed to survive 50–100 shipment cycles, these durable mailers use zippers or snaps instead of disposable adhesives and can be returned, cleaned, and reused.

They’re ideal for rental and subscription services where returns are expected. For example, Rent the Runway ships fashion items in reusable garment bags, and other styling services now offer reusable mailers at checkout. 

While EcoPackables primarily offers compostable and recycled single-use mailers, we also support brands by offering custom reusable mailers made from GRS certified recycled materials. Some retailers even incentivize returns of empty mailers with discounts. This approach reduces waste and enhances customer experience while turning logistics into a sustainable service.

Reusable mailers are especially well-suited for fashion rentals, high-end apparel, and other recurring delivery models, offering a premium, eco-forward experience and helping brands close the loop on packaging waste.

Choosing the Right Packaging for Your Returns Process

With multiple return-friendly options available, how should a company decide which packaging to use? The choice will depend on your industry, product characteristics, return rates, and sustainability goals. Below is a breakdown to guide decision-making:

Fashion/Apparel (Moderate to High Return Rates):

For most clothing brands, flat mailers with dual adhesive strips are a smart default. They are lightweight (keeping shipping costs down) and easily store-able, and apparel isn’t fragile so it doesn’t require padding. If your brand identity is eco-focused, opting for a compostable or recycled flat mailer resonates with customers. Using mailers that facilitate returns will significantly reduce headaches for your customers and your operations. Make sure to include a prepaid return label in the shipment or offer easy label printing online to complement the returnable mailer. In general, apparel companies should ask: Will my customer need to return or exchange items often? If yes, prioritize packaging that can be opened without damage and resealed securely.

Personal Styling & Subscription Services:

Businesses like styling subscriptions or “try-before-you-buy” services (Stitch Fix, Trunk Club, etc.) often send multiple items in one shipment and expect some to come back. Here, planning for returns is integral to the experience. If you ship in a larger box or kit, consider including an extra EcoPackables mailer (e.g., a flat or padded mailer made of recycled material) plus a return label for the items the customer doesn’t keep. This approach was used by thredUP and MM LaFleur to streamline returns. Alternatively, use a durable reusable bag as the primary packaging – for example, a styling service might send clothes in a chic reusable tote or fabric mailer that the client uses to send back unwanted pieces. This can elevate your brand image (it feels like a value-added service) and underscores your commitment to sustainability. Just ensure you have a clear system to track and refurbish these reusables when they come back. The key is to make returns extremely easy for the end user, as that convenience will encourage them to keep using your service.

Electronics, Cosmetics & Fragile Goods:

Companies dealing in breakable or sensitive items should lean toward padded mailers or corrugated boxes with protective inserts, but still incorporate return-friendly features. A small electronics gadget, for instance, could ship in a padded mailer that has a bubble lining and dual seal strips. If the customer needs to return it, the padding is already there to protect it on the way back – reducing the chance of damage and avoiding extra packing materials for cushioning. If using boxes (common for electronics), design them with tear-open strips which don’t get destroyed in the unboxing process and are easy to reseal with tape. You could even include a spare sealing tape strip for returns. 

Next steps

  • In sum, choosing the right packaging for returns is about balancing protection, cost, and ease-of-use for the customer. Start by analyzing your return patterns: Are returns almost certain (as in rentals)? Are they occasional but significant (apparel/footwear retail)? Or rare (certain niche products)? Then select the packaging solution that makes that return pain-free. Don’t forget to factor in branding and education – use graphics or text on the package to tell customers “This mailer is reusable – please use it if you return your items” or instructions like “Peel here to reseal for returns”. EcoPackables can customize such messaging on your packaging, turning it into a mini-lesson in sustainability for your customers. When customers see that return logistics were anticipated and made simple, it boosts their confidence in your brand.

  • Finally, keep an eye on emerging technologies and services in reverse logistics. Innovations like QR codes on packaging that trigger a return pickup request, or smart packages with tracking for reuse, are on the horizon. Designing today’s packaging to be return-friendly is the first step toward a more circular supply chain. It reduces waste in the short term and positions your company for the future of sustainable commerce. With EcoPackables’ range of eco-conscious mailers – from flat mailers with dual adhesive strips, to padded mailers, to the promise of fabric reusables – you have the tools to make your returns process greener and more efficient from start to finish. By choosing the right packaging for reverse logistics now, you’re not only saving costs on return packaging and earning customer goodwill, you’re actively contributing to a solution for the e-commerce waste problem one mailer at a time.
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