Garment Packaging Inserts Guide: Tissue Paper, Backing Cards & Dust Bags

Garment packaging inserts are the second thing a customer sees after opening the bag, right after the hang tag. They decide whether a garment arrives creased, colour-stained or snagged in transit — and whether unboxing feels clean and considered or cheap and careless. Many brands spend their whole budget on hang tags and outer bags while neglecting this middle layer, and that is exactly where the unboxing experience breaks down.

This guide breaks down tissue paper, backing cards, rigid board, dust bags and hangers by material, weight and use case, then covers cost control and a pre-order checklist — so your inserts become one coherent packaging programme rather than scattered purchases.

1. What Packaging Inserts Actually Do

Inserts are not optional filler — they solve four problems at once:

• Holding the shape — folded shirts and knitwear without support arrive with hard creases that stores must press out again;
• Separation and protection — friction between garments and cartons causes snags and colour transfer, especially with satin, lace or mixed dark and light packs;
• Carrying the brand — logo-printed tissue paper, belly bands and backing cards are the cheapest recurring brand touchpoint you can buy;
• Supporting display — retail and gift channels rely on backing cards, hangers and dust bags so garments look tidy the moment they are hung.

2. Common Inserts and Accessories at a Glance

3. Tissue Paper: Weight, Size and Printing

Tissue paper is the most common insert and the easiest to get wrong. Cheap wrapping paper bleeds and goes brittle; on white silk or pale fabric that means reworking a whole batch.

• Weight: 17–20gsm is light and supple for wrapping; 25–30gsm is firmer and better as a lining or gift-box layer;
• Size: add 10–20mm per side to the largest folded dimension so the paper folds in and holds the edge;
• Printing: single-colour logos are the norm; ask for eco soy-based ink and always confirm no rub-off on dark garments;
• Do not substitute ordinary wrapping paper: it bleeds, tears easily and contaminates fabric.

4. Backing Cards: E-commerce and Retail Need Different Logic

E-commerce fulfilment wants bags that lie flat and stay light; retail display wants stiffness and a tactile feel. The same garment can use completely different backing cards per channel.

• E-commerce, folded into a bag: 250–300gsm board is enough; match the card to the inner bag width to avoid bulging or wasted space;
• Retail and gift boxes: 350–400gsm board, matt-laminated, resists bending and takes a debossed logo;
• Shirts, scarves and ties usually use a backing card with clips or cotton string;
• Hats, gift boxes and shoeboxes use 2–3mm grey board inserts die-cut to the product contour.

5. Dust Bags and Greener Alternatives

• Non-woven: 60–80gsm is the usual band, with drawstring or flap and hook-and-loop closure — the best cost-to-feel balance;
• Cotton or cotton-linen bags cost more but suit gifts, limited editions and premium leather goods;
• PE bags are the cheapest option, but the EU and other markets restrict plastic packaging, so check before exporting;
• PLA and PBAT compostable bags are a good inner layer rather than an outer one, because their tear strength is lower.

6. Cost Control Without Cheapening the Pack

• Order one paper and one colour: hang tags, backing cards and tissue sharing a single paper shade cut setup and colour-matching work;
• Standardise insert sizes: two or three common formats can cover a whole range and save extra die costs;
• Fewer spot colours and less lamination: a single-colour logo on natural stock often looks better and greener than four-colour laminated print;
• Consolidate quantities: combine standard inserts with hang tags in one order to spread MOQ and freight costs.

7. Pre-Order Checklist

• The folded length, width and thickness of the garment;
• Whether the insert carries a logo, in one colour or four;
• Material and weight (tissue, white board, grey board, non-woven);
• Any eco certification or compostability requirement, and whether the export market restricts plastic;
• Whether it shares one colour reference and paper with the hang tag and paper bag;
• Sample approval (3–7 days) and bulk lead time (10–25 days).

Related reading

• Complete garment packaging guide — how inserts, bags, tags and cartons fit together.
• How to choose packaging bag types — matching outer bag material and insert size.
• Packaging design system for clothing brands — building inserts into one visual language.
• Back to the Trims FAQ for more articles on hang tags, woven labels, care labels and packaging.