Maxi-Letter Carton

Does a maxi letter carton fit?

• A maxi letter carton lets you ship flat, lightweight goods (up to 50 mm height, under 1 kg) at letter rate instead of parcel rate within Germany. If you regularly send small items, this saves postage on every shipment.
• Seven sizes from 180 × 100 × 30 mm to 350 × 250 × 50 mm, in brown and white, with a tab-lock closure that needs no tape, made from E-flute corrugated board.

In Germany, a "Maxibrief" is a postal category for flat shipments up to 353 × 250 × 50 mm and 1 kg. Any box that stays within these limits qualifies for letter-rate postage. The cartons in this category are built to match those limits exactly.

• If your item is flat (under 50 mm) and weighs less than 1 kg including the box, a maxi letter carton is the right choice.
• If the product fits into one of the seven available sizes without the lid bulging, the carton works.
• If your shipment is thinner than 20 mm and under 500 g, a standard letter carton may be cheaper.
• If your item weighs more than 1 kg or exceeds 50 mm in height, you need a single-wall shipping carton.
• If you are shipping fragile goods and the box alone is not enough, add lightweight cushioning: tissue paper orbubble wrap.

How to choose the right size

Inner dimensions vs. product size

The inner dimensions determine whether your item fits. Not the outer dimensions.

• Measure your item including any cushioning material.
• Compare the inner dimensions from the product data with your item.
• Allow a maximum of 5 mm clearance per side. Too much space lets the item shift; too little makes the lid bulge.
• If the fit is borderline, choose the next size up.

Weight: carton plus contents

The carton has its own weight, which counts towards the 1 kg maximum. Larger sizes weigh more than smaller ones.

• Subtract the carton weight from the maximum allowance.
• Factor in the weight of any cushioning material.
• If weight is borderline, try the next smaller size. Smaller cartons are lighter.

Brown or white

Brown is cheaper because it is unbleached. White looks more polished and works well for customer-facing shipments.

• For warehouse use, returns or B2B: brown is fine.
• For gifts or branded products: white.
• Both colours can be printed if you need maxi letter cartons with your logo.

Closure and assembly

All maxi letter cartons in this range have a tab-lock closure (FEFCO 0426). No tape needed, assembly takes seconds.

• For heavier contents, add a strip of paper tape across the tab for extra security.
• Push the tabs in fully until they click into place.
• The cartons ship flat. Store them upright to save space.

Will it fit through the recipient's letterbox?

Standard German letterbox slots are roughly 30 to 40 mm tall. Only the flattest sizes (up to 35 mm outer height) fit through reliably.

• Check whether the recipient expects letterbox delivery.
• Cartons taller than 40 mm may require collection from a post office or parcel locker.
• DHL Packstationen (parcel lockers) accept all maxi letter carton sizes.

Cushioning

The E-flute board and the carton edges protect most items sufficiently. For sharp-edged or fragile goods, plan for lightweight cushioning.

• Tissue paper or thin bubble wrap for delicate surfaces.
• Avoid heavy cushioning material. The total weight must stay under 1 kg.
• Fill any voids so the contents cannot shift.

All seven sizes at a glance

Four typical use cases

Return-friendly shipping

If customers need to return items easily: the tab-lock closure allows reuse without tape. The recipient needs no tools and can use the same carton for the return.

Shipping to DHL Packstationen

If the recipient is not home during the day: all maxi letter carton sizes fit into DHL parcel lockers (Packstationen). Delivery success rate goes up, fewer shipments bounce back.

Seasonal high-volume campaigns

When order volume spikes, every second of assembly time counts. Maxi letter cartons ship flat and need no tape dispenser. Ideal for pre-picking on pallets.

Sensitive electronics

For static-sensitive goods or sharp edges, the E-flute alone is not enough. Place the item in an anti-static bag plus tissue paper, and choose one size up so the cushioning fits.

Common ordering mistakes

1. Checked outer instead of inner dimensions. The item does not fit, the lid bulges. Fix: always compare inner dimensions with your product (see "Inner dimensions vs. product size" above).
2. Ordered only the largest size as a catch-all. Most items are smaller, so you overpay on postage and need filler material. Fix: analyse your product mix and stock two to three sizes.
3. Forgot to account for cushioning weight. Add up the weight of carton plus cushioning before shipping (see "Weight" above).
4. Stored white cartons in a damp warehouse. Discolouration, unprofessional appearance. Fix: store dry and upright. In humid conditions, choose brown.
5. Sent a 50 mm carton expecting letterbox delivery. It does not fit through the slot. Fix: for letterbox delivery, choose a size with a maximum outer height of 35 mm (see "Letterbox" above).
6. Tabs not fully locked in. The carton opens during transit. Fix: press tabs all the way in. For heavy contents, add a strip of tape across the tab.

Accessories and related categories

Related shipping options

• Standard letter carton (Großbrief): for thinner, lighter shipments under 20 mm and 500 g.
• Book packaging: for form-fitting book shipments.
• Shipping box: when maxi letter dimensions are not enough.
• Single-wall carton: for heavier or larger shipments.
• Custom-size carton: when no standard size fits.

Frequently asked questions

What exactly is a "Maxibrief"?

Maxibrief is a German postal category for flat shipments up to 353 × 250 × 50 mm and 1 kg. Sending at this rate is significantly cheaper than parcel shipping. The cartons on this page are sized to fit within those limits.

What does FEFCO 0426 mean?

FEFCO 0426 is a standardised box type with a tab-lock base and lid. It does not require tape for closure and can be opened and reclosed multiple times without damage.

What is E-flute corrugated board?

E-flute (also called micro-flute) has a wave height of roughly 1 to 1.9 mm. It is sturdy enough for lightweight goods while keeping the overall carton height low.

How do I label a maxi letter carton correctly?

Place the recipient address on the top face. The sender address goes on the top face or on one of the narrow sides. Write legibly. Avoid handwriting on dark cardboard.

Do maxi letter cartons stack on a Euro pallet?

Yes. They are delivered flat and stack efficiently. The exact number per pallet depends on the carton size.

Can I drop a maxi letter carton into a public postbox?

Yes, as long as the carton fits through the slot. The flatter sizes (up to 35 mm outer height) fit into standard Deutsche Post postbox openings.

What happens if my shipment exceeds the Maxibrief limits?

The carrier may reclassify it as a parcel and charge the recipient additional postage. Weigh and measure before shipping to avoid this.

Can I send a maxi letter carton as a BÜWA (Bücher- und Warensendung)?

Yes, if the shipment contains only goods plus an invoice or delivery note and is marked as "BÜWA." Personal letters or messages are not allowed in a BÜWA shipment.