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Cahoot stocks a wide range of standard boxes and mailers at every fulfillment center, and the most appropriate option is automatically selected for each shipment. If standard packaging doesn't meet your needs, you have two alternatives: Custom Packaging (Cahoot sources non-standard boxes or mailers on your behalf) or Branded Packaging (you provide your own boxes, mailers, or supplies and ship them to a Cahoot warehouse via inbound).

Important: Both Custom and Branded packaging require prior approval from Cahoot and incur additional storage and handling fees. Do not purchase or commit to any packaging before completing the approval process below.
Required Reading: Review Standard Packaging Available at Cahoot Locations first to confirm whether a standard size already fits your product.

When You Might Need Custom or Branded Packaging

Consider Custom or Branded packaging if any of the following apply to your products or business:

  • Product size: Items too large for Cahoot's standard box or mailer dimensions.
  • Special protection: Fragile items requiring heavy-duty boxes, side-loaders, or specialized inserts.
  • Brand experience: Premium unboxing with branded boxes, mailers, tissue paper, or marketing inserts.
  • Unique shapes: Products needing non-standard configurations or multi-depth boxes.

Approval Process

Before sourcing or shipping any custom or branded packaging, you must request approval from Cahoot. Approval is based on your monthly order volume, operational feasibility, and the technical specifications of the proposed packaging.

1Submit a request by Submit Ticket describing the packaging you want to use and the reason.

2Volume assessment. Cahoot evaluates your monthly order volume and the impact on fulfillment efficiency.

3Technical review. Cahoot confirms the packaging meets size, label, and handling requirements (see specs below).

4Cost analysis. Cahoot shares the additional fees and any minimum commitments before you proceed.

Technical Specifications

All custom and branded packaging must meet these requirements to work with Cahoot's fulfillment operations:

  • Maximum mailer size: 18 inches length × 14 inches width.
  • Label space: Minimum 6" × 4" flat surface for shipping labels.
  • Structural integrity: Packaging must hold its shape during automated handling.
  • Material restrictions: No materials that interfere with scanning or labeling systems.

Custom Packaging (Cahoot Sources)

Custom packaging refers to non-standard boxes or mailers that Cahoot purchases on your behalf. Choose this option when standard sizes don't fit your product but you don't need branded materials. Cahoot handles the sourcing, sample approval, bulk purchasing, distribution to fulfillment centers, and ongoing inventory management — you do not need to create packaging entries yourself.

1After approval, share your packaging specifications with Cahoot.

2Cahoot sources options and provides cost estimates.

3Review and approve packaging samples before bulk ordering.

4Pay the upfront cost — Cahoot purchases the packaging and distributes it to the appropriate fulfillment locations.

5Cahoot tracks usage, notifies you when reordering is needed, and assigns the packaging to your SKUs.

Note: Cahoot can also source additional shipping supplies on your behalf — kraft paper, cushioning, branded stickers, tissue paper, and dividers or inserts. The same approval and cost process applies.

Branded Packaging (You Provide)

Branded packaging refers to your own boxes, mailers, or supplies — typically printed with your logo or designed for a custom unboxing experience. With branded packaging, you handle sourcing and quality control, then ship the materials to a Cahoot warehouse via inbound.

1Confirm you have written approval from Cahoot before purchasing any branded materials.

2Create packaging entries in your Cahoot account. See Creating Packaging & Shipping Supplies.

3Include the packaging with your inbound shipment. See How to Add Packaging to Your Inbound.

4Monitor your packaging inventory and include replenishments with future inbounds. Use the Optimizations Report to track usage.

track usage
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What Happens If You Run Out

If your branded packaging runs out at a Cahoot fulfillment center, the following defaults apply:

  • Cahoot will continue shipping your orders using standard packaging.
  • Orders will not be held automatically — if you want orders held until branded packaging is replenished, you must contact support to request that.
  • Cahoot does not send automatic low-stock notifications for branded packaging.
  • Storage fees continue to apply even when branded packaging is out of stock.
Tip: Set a regular cadence to review your branded packaging levels and include replenishments with scheduled inbounds to prevent stockouts.

Questions?

To start the approval process or discuss whether Custom or Branded packaging is right for your business, Submit Ticket.

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