For many small online sellers, November and December bring more orders than the rest of the year combined. The busy season is exciting, but it also exposes every weak spot in your packing and shipping routine. This holiday shipping checklist walks you through what to do in October, November and December so you’re stocked, organized and ready when orders spike.
A tidy packing station saves time on every holiday order.
October: Forecast Volume and Order Supplies
Estimate your order count
Look at last year’s orders for November and December, then adjust for how your shop has grown since. If you’re new, use your recent weekly average and plan for a meaningful bump around the big sale weekends. A rough forecast is far better than none.
Turn orders into supply numbers
For each product, note which mailer or box it ships in. Multiply your forecast by that, then add a buffer for re-ships, exchanges and packing mistakes. Do the same for tape, labels, filler and thank-you inserts.
Order early
Packaging demand rises across the industry in the fall. Placing your main order in October gives you time to check that the sizes are right and to top up before the rush. Our packaging supply checklist for small businesses is a handy list to work from, and why buying packaging wholesale explains how bulk ordering fits into planning.
Stock Poly Mailers by Size
Most small sellers ship a handful of products over and over, so you don’t need every size. Pick the two or three sizes that cover 80–90% of your orders and stock those deepest. Our poly mailer size guide shows what typically fits in each size.
| Mailer size | Typical contents |
|---|---|
| 6 x 9 in | Jewelry, accessories, small cosmetics |
| 7.5 x 10.5 in / 9 x 12 in | T-shirts, socks, small soft goods |
| 10 x 13 in / 12 x 15.5 in | Hoodies, leggings, folded apparel |
| 14 x 17 in / 14.5 x 19 in | Jackets, bundles, multi-item orders |
| 19 x 24 in / 24 x 24 in | Bedding, bulky soft goods, large bundles |
Our poly mailers come 100 per roll. Popular picks for holiday apparel include the 2 mil 9 x 12 in mailer with tear strip and the 2 mil 12 x 15.5 in, with the 2 mil 19 x 24 in for big bundles.
2 Mil vs 3 Mil: Which Thickness for Holiday Orders?
- 2 mil is the everyday choice for clothing and soft goods. Our 2 mil mailers come with a tear strip.
- 3 mil gives extra toughness for heavier orders, items with corners or shipments that go through more handling. We stock 3 mil from 6 x 9 in up to 24 x 36 in, including the 3 mil 14 x 17 in.
Read how to choose the right poly mailer for a deeper look at thickness. If you also ship fragile items, compare poly mailers vs bubble mailers before the rush.
Set Up a Holiday Packing Station
A good packing station saves seconds on every order, and those seconds add up fast in December.
- One flow, one direction: products in on one side, sealed packages out on the other.
- Mailers within arm’s reach, sorted by size with the most-used size closest.
- Printer and labels next to the scale.
- A printed size cheat sheet so helpers know which mailer fits which product.
- A small bin for damaged or mis-sized mailers so they don’t end up back on the table.
Oversized packaging can quietly raise your postage. Our post on dimensional weight and shipping costs explains how a snug mailer can help keep postage down.
Sort mailers by size and keep the most-used one closest.
Palletized Shipments: Inbound Stock and Wholesale Orders
If you receive inventory on pallets or send wholesale orders to retailers, wrap loads firmly so they arrive intact during the busiest freight season. A hand roll like the clear 18 in x 1500 ft, 80 gauge hand film covers most pallets, while a 12 in roll is easier for small bundles and boxes in the stockroom.
A 12 in hand film roll is easy to handle for small bundles and stockroom jobs.
Not sure how much film to plan for? See how much stretch film you need per pallet.
Carrier Deadlines and Customer Communication
- Check your carrier’s holiday deadlines as soon as they’re published, and set your shop’s “order by” dates a day or two earlier.
- Post your cut-off dates on your site banner, product pages and order confirmation emails.
- Plan for weather and volume delays by setting realistic delivery estimates.
Extra hands for peak weeks
If friends, family or seasonal helpers will be packing, train them in early November, not the week of the big sale. Walk them through your size cheat sheet, show them how to seal and label correctly, and keep a copy of this holiday shipping checklist taped to the wall. A short daily routine, such as restocking mailers at the end of each shift and emptying the trash bin, keeps the station ready for the next morning.
Holiday Shipping Checklist for Returns and Exchanges
January returns are part of the season. Keep a stock of mailers set aside for exchanges and re-ships, write a clear returns page, and include a short note in each package explaining how to start a return. Our essential shipping supplies list covers the rest of the basics.
Frequently Asked Questions
When should I order holiday shipping supplies?
October is a good target. It gives you time to confirm sizes, spot gaps and reorder before peak weeks.
How many mailers should I stock?
Start with your forecast order count for each mailer size, then add a buffer for re-ships, exchanges and mistakes.
Do I need 3 mil mailers for the holidays?
Not always. 2 mil handles most clothing. Use 3 mil for heavier orders or items with corners.
Ready to stock up for the season? Request a wholesale quote for mailers and stretch film.
