HexClad Built a 7-Figure Programmatic Direct Mail Program with PostPilot

Industry:
Home & Garden
In Partnership With:
Shopify
,
Klaviyo
,

TLDR:

The story of HexClad x PostPilot is one of testing, iteration, and expansion. What started as a seasonal tactic has grown into a core marketing channel.

  • Early success with direct mail in 2022 led Hexclad to scale into BFCM, driving $1.7m over BFCM 2022.
  • In 2023, HexClad ran additional tests in the months leading up to BFCM and scaled direct mail further over Q4, driving $2.9m (66.3% YoY) over BFCM 2023.
  • Following BFCM 2023, HexClad has expanded their evergreen campaigns, testing and launching a number of direct mail automations for a “set it and forget it” retention and acquisition solution.

Background:

HexClad started working with the PostPilot team in 2022, initially looking to test a new channel before BFCM. They were able to test into direct mail with a modest budget, allowing them to validate the channel and specific audiences that performed best.

Learnings from those tests led the team to heavily scale direct mail into BFCM ‘22, which yielded remarkable results and showed direct mail’s power of scale: they drove over $1.7M in revenue. 

That was just the beginning.

In 2023 and 2024, HexClad has done much more with direct mail.

Throughout the year, Hexclad continued to run a variety of campaigns, ramping up more testing in the weeks leading into BFCM ‘23. Using that data, they could confidently launch massive BFCM campaigns, ultimately increasing YoY revenue by 66%. 

After the second BFCM triumph, the team further expanded testing, implementing a number of automated, evergreen retention campaigns to trigger a personalized card based on particular behavior.

“Our strategy for direct mail is constantly evolving. We’re able to continue building on what we found has worked, but there's always something new to test.”

-Andrew Windle, Director of Retention @ HexClad

The PostPilot Solution:

Blowing Away BFCM (Again)

For BFCM ‘23, The HexClad team sent targeted postcards to their entire funnel—from never-purchasers to (seemingly) lapsed high-value customers. 

On the acquisition side, the team used MailMatchTM to convert leads who had subscribed to their email list but had not purchased yet. MailMatch lets brands send direct mail campaigns to the homes of leads based on email addresses alone.

Specifically, they built a three-card MailMatch flow, much like a welcome flow—if someone converted after receiving two cards, they would not recieve a third.

HexClad direct mail postcard that says "Shop our exclusive Black Friday Cyber Monday Sale! Save up to $1600 on select bundles and up to 50% on individual products. Join the biggest savings with $100 off 12pc set and more!"
The 4x6 postcard HexClad sent using MailMatch

Then, to boost LTV, the team sent postcards to dormant VIPs, including those unengaged with email/SMS. Although those unsubscribed VIPs weren’t reachable via owned channels, HexClad connected with them at home using first-party purchase data.

HexClad postcard that says "BLACK FRIDAY CYBER MONDAY SALE! Louis, the biggest deals of the year have arrived. Don't miss out on upgrading your collection. Save up to 50% off sitewide!" On the right is a HexClad pan that appears to be filled with chopped potatoes and 3 poached eggs. There is a HexClad knife next to the pan.
Example of a 4x6 postcard sent to VIPs

“One of the things I've really enjoyed about my time working with the PostPilot team is using your concierge design services in conjunction with our own designs. We have a strong attention to detail as a luxury brand, and it’s something that your team’s done extremely well with.”

-Andrew Windle, Director of Retention @ HexClad

From Seasonal Sends to Evergreen Automations

After seeing major success over BFCM ‘23, the HexClad team has launched seven automations that continue to drive hands-off, high-ROI results, including:

  • Abandoned carts: Dynamically sending cart abandoners (who completed HexClad's Klaviyo abandoned cart flow without purchasing) a postcard.
  • Winbacks: Sending campaigns to several customer cohorts based on recency and frequency. They can track the performance of each cohort directly in their dashboard.

Brands work with their account manager and data experts at PostPilot to identify the automations that should work best for them. Then, PostPilot designs (or helps design) mailers for each campaign, launches them, and makes additional recommendations based on performance. 

As with all other marketing, we keep what works, nix what doesn’t, and continue to test to identify additional opportunities.

The Results:

“Direct mail is a focus for us, and it does great in ways that traditional retention channels can't. We can do the same sort of surgical targeting that we're spoiled by on the digital side.”


HexClad’s scaled seasonal sends and expanded programmatic direct mail campaigns have performed remarkably well.

Over ~4 months, direct mail generated:

  • $3.2m in revenue
  • 12x+ ROAS

Win-win. 

What started as a marketing opportunity grew into an always-on growth channel.

HexClad has acquired new customers they weren't reaching on digital and reactivated long lapsed, unengaged customers.

  • In one BFCM ‘23 campaign, they saw a 2%+ CVR among VIPs who hadn’t purchased in between 530 and 730 days. 

And by maintaining direct mail as a pillar of their marketing strategy, they can continue to drive results until the next major holiday rush. 

We expect that it will be even bigger than last year.

Bonus question for HexClad: How would you describe PostPilot to someone who’s never heard of us?

“Direct mail for the digital age.”

Next Case Study

Indoor Peak Saunas infrared sauna shown in a modern home setting. Text reads “You Left Something Behind” with messaging about relaxing at home and a free essential oil gift with sauna purchase using a promo code.

Peak Saunas Turns Up the Heat with Direct Mail

The medical-grade infrared sauna maker sees off-the-charts results with net-new and repeat revenue.

Front of a MaryRuth’s postcard with the headline “Wellness Awaits!” Three Liposomal multivitamin bottles—Women’s, Men’s, and Kids’—are shown next to a glass of orange liquid being poured. Clean Label Project badge appears near the top.

MaryRuth’s Drives Shopify + Amazon Revenue with PostPilot

The liquid vitamins and supplements brand is seeing incredible success across sales channels with direct mail.

Composite image showing two Criquet Shirts postcards designed and printed by PostPilot. The left postcard features a smiling man in a black slim-fit polo standing in a doorway with a drink, alongside the headline “The Results Are IN!” and a 20 percent off

Criquet Stacks Wins with Klaviyo, Digioh, and PostPilot

The apparel brand leverages tech partners for hyper-segmented and hyper-personalized experiences that drive incredible ROI.

Direct mail postcard from VKTRY Performance Insoles showing a football player in a yellow helmet and white uniform holding a football. Headline reads ‘Invest in Your Performance’ with messaging about athlete-designed insoles, a 90-day money-back guarantee,

VKTRY Gear Automates Incremental Revenue with PostPilot

The performance insoles brand successfully retargets and retains more customers with direct mail.

A Diane von Furstenberg postcard featuring a model lounging sideways on a mustard-yellow curved sofa. She wears a matching geometric blue-and-white printed top, pants, and headscarf, with black heeled sandals. Sunlight streams through a nearby window, cast

Diane von Furstenberg Uses PostPilot for High-ROI Customer Retention

The legendary fashion brand chose PostPilot to drive extremely profitable repeat purchases.

mugsy postcard that says "happy birthday, dude! What? You thought we would forget? Never." To the right is a man yelling with joy holding a pin

Mugsy Drives Net-New and Repeat Revenue with PostPilot

The beloved jeansmaker uses direct mail to retarget and retain customers.

Interior of a ghostbed trifold cardalog showing a message from cofounder (Marc Werner) on the left and best-selling products in the middle and right panels.

GhostBed Runs Lifecycle Marketing with PostPilot

The mattress brand uses direct mail to nudge almost-buyers to purchase and win back previous buyers.

Still of Emily Roberts, VP of Growth Marketing at Roswell, being interviewed for a case study.

Roswell NYC Powers Its Customers’ Direct Mail Programs with PostPilot

The award-winning agency uses PostPilot to drive new and repeat revenue for its brand portfolio.

Still of interview with Jess Chan, founder of Longplay Brands, from interview with PostPilot.

Longplay Brands Enhances Customers’ Lifecycle Marketing with PostPilot

The email/SMS experts add direct mail to offer unified owned marketing to their brands.

Still of Albert Mattheny IV, Promix Co-Founder, in interview with PostPilot.

Promix NutritionⓇ Converts Customers Unsubscribed from Email with PostPilot

The beloved supplements brand uses PostPilot to drive strong incremental results in their lifecycle marketing

Petite Keep Postcard by PostPilot featuring collaboration trunk of Peter Rabbit and Petite Keep. The trunk is a light purple, opened, and says "Maggie" in subtle light pink lettering inside. In front of the trunk features an array of Peter Rabbit products

Petite Keep Unlocks an “Heirloom-Worthy” Channel with PostPilot

The rapidly rising DTC star uses direct mail to deliver greater personalization and build genuine connections through its marketing.

Two adorable dogs relaxing comfortably on a Big Barker dog bed, with text reading 'Backed By Science. Loved By Dogs' and a promotional offer for a free cooling upgrade.

Barker Beds Leans into Direct Mail Retargeting to Drive More First Purchases

The vet-recommended dog bed maker uses SiteMatch and MailMatch to retarget and convert non-buying leads.

Still of Mark Milutin, founder of Bread Loaf, in his interview with PostPilot.

Bread Loaf Powers Multiple Shopify Brands’ Lifecycle Marketing with PostPilot

Bread Loaf uses direct mail to add another marketing pillar to its clients’ strategies.

Still of Peter Bacon (CMO of Clocks + Colours) being interviewed by PostPilot.

Clocks and Colours + Vitaly Design Retarget and Retain More Customers with PostPilot

The jewelry brands use direct mail to plug their retargeting funnels and reach unreachable customers.

A postcard from Made In featuring professional chefs in their kitchens using premium cookware, highlighting 'Your Favorite Chef's Favorite Cookware' along with a QR code for recipes and videos.

Made In Automates Incremental Retargeting + Retention Revenue with Direct Mail

The chef-quality cookware brand uses PostPilot to drive first and repeat purchases year-round.

Still of interview with Salem McLaughlin (Sr. Manager - Ecommerce) in his interview with PostPilot.

Laird Superfood Doubles Down on Direct Mail with PostPilot

A longtime customer, Laird has leveraged direct mail to reliably reengage customers, and fight subscription churn.

Still of Zak Cassady-Dorion being interviewed for case study with PostPilot.

ECD Digital Strategy Drives High-ROI Direct Mail Wins for Its Customers with PostPilot

ECD Digital Strategy uses direct mail across many of its brands, across several verticals.

A postcard with handwritten-style text: "Hi Justin, I want to personally thank you for trusting us as a beneficial resource for your health. Anytime you need help placing orders or have questions about a product, we're only a phone call away. Keep this car

Country Life Natural Foods Drives (Way) More Healthy Eating with Direct Mail

Mitchell Hagan and Isaac Lewin Country Life Natural Foods share their wins with direct mail and the PostPilot team.

Caddis postcard featuring two thirty–fortysomething people. Postcard says "Get Older. Own it. See stuff. Get $25 off your next order."

Caddis Sees Major Retargeting + Retention Wins with Direct Mail

The anti anti-aging eyewear brand uses PostPilot to drive first purchases and keep customers coming back for more.

Still of Anna Brakefield (founder Red Land Cotton) from interview with PostPilot.

Red Land Cotton's Direct Mail Success Story

Anna Brakefield, founder of Red Land Cotton, and agency partner Liam Veregin from Aplo Group discuss what PostPilot has unlocked for the brand.

Cataloging Cozy Earth’s Massive Direct Mail Success

The luxury bedding and loungewear brand has driven millions in incremental full-funnel revenue with PostPilot.

Postcard from Four Sigmatic showing product imagery on the left, including a bag of Think organic cofee, as well as a cup of coffee being poured from a french press. On the right is the brand logo and the headline "Upgrade your coffee" and text below that

Four Sigmatic Drives 57% Increase in Sales Velocity at Whole Foods Using Direct Mail

The functional foods brand sent postcards to a PostPilot-built lookalike audience that substantially increased Whole Foods sales.

Direct mail postcard from The Beard Struggle advertising a Black Friday sale. Beard grooming products are displayed in front of a stone arch with flames in the background. Text promotes up to 60% off selected items and highlights a limited-time discount co

The Beard Struggle Slashes Through Digital Noise with Direct Mail

The beard care brand for the modern viking leverages direct mail as another pillar of their retention program.

MASA postcard showing their brand name written at the top in white letters, overlaid on a picture of a backyard pool with a blonde-haired woman in the foreground holding a MASA bag. At the bottom, there is information about a code that can be used.

Ancient Crunch Puts Retargeting + Retention on Autopilot with PostPilot

The “FritoLay of real food” is driving more first and repeat purchases with automated direct mail campaigns.

kindred bravely postcard that says, "thank you for celebrating with us!" in larger font at the top, and says, "You joined our 9th Birthday Party celebration, and we have a party favor for you! Use your code to take 25% off an order of $100 or more before M

Kindred Bravely Powers Shared Mail + Full-Funnel Wins with PostPilot

The beloved nursing and maternity wear brand uses direct mail to acquire more customers, retarget them, and keep them buying.

Gozney A5 postcard that has an offer for the Dome or Dome S1, which includes a free placement peel and cover. Text says, "Give the gift of fire." Dates for the offer are shown as between November 13 and December 14.

Gozney Fires UK BFCM Wins with Direct Mail

Gozney leverages PostPilot to retarget and retain UK customers.

TM Lewin postcard that says "Shop our black friday sale. Up to 70% off"

Direct Mail Is a Perfect Fit for T.M. Lewin’s UK Retention Program

The 126-year-old men’s formalwear brand uses postcards to win back UK customers at strong ROIs.

Marketing graphic illustrating PostPilot’s AcquisitionAI. A central ‘AI’ node connects to audience attributes such as age range, income level, home ownership, shopping behavior, and hobbies, which then link to multiple customer profile icons.

9-Figure Women’s Apparel Brand Uses AcquisitionAI For Best-in-Class Direct Mail Prospecting

PostPilot’s proprietary targeting tech drove 124% stronger results than the leading consumer data provider for a major women’s apparel brand.

horizontal 4x6 inch postcard that says "toty. We miss you, william! preserve your skin health and feel más bonita inside and out with this exclusive offer: save 15% sitewide." below is a code and a prompt to "shop now at toty.com"

Direct Mail Shines in Toty’s Marketing Mix

Sophia Vergara’s suncare brand is leveraging direct mail for retargeting and retention, at 4x+ ROIs.

Direct mail postcard from &Collar with large ‘Thank You’ text. A man in a white dress shirt reacts as a drink spills onto his shirt at a counter with lemons and a blender, emphasizing stain-resistant fabric.

&Collar Drives 6 Figures Sending Handwritten Cards to VIPs

As part of its full-funnel direct mail program, &Collar sends high-ROI handwritten cards as a special “thank you” to VIP customers.

Postcard from Lo & Sons promoting the Waverley 2 crossbody bag, in a variety of colors.

Lo & Sons Leverages Segments Analytics & PostPilot to Drive Second Purchases

The travel bag experts mailed customers specific cross-promotions based on first purchase behavior, affordably driving repurchases.

portland leather goods postcard that says "WELCOME BACK 30% OFF" to drive repeat purchases among multibuyers.

Portland Leather Goods Bags 8 Figures with Full-Funnel Programmatic Direct Mail

PLG’s direct mail program with PostPilot drives major revenue and automates birthday offers to VIPs.

The front features a bold photo of a woman wearing unbuttoned high-waisted blue jeans, cropped at the chest, with the Good American logo across the denim.

GOOD AMERICAN Makes the Switch to Full-Funnel Revenue with Direct Mail

The body-positive apparel brand switched to PostPilot to improve performance and unlock a full-funnel channel.

Postcard designed and printed for KURU by PostPilot that says "Hey there, Melissa! We've added new styles since you last purchased."

KURU Footwear Notches $2m+ with Full-Funnel Direct Mail

In their first year with PostPilot, the foot pain fighters drove 7 figures in revenue at a 10x+ ROI.

Taylor Stitch postcard printed by PostPilot that says, "Now's your time to save big. Save 20%. On responsibly built shirting, outerwear, basics, and more."

Taylor Stitch Automates Retention and Revenue with PostPilot

The responsible shirting brand has driven 7 figures in seasonal and programmatic revenue using direct mail.

4x6 postcard that M&S Meats sent over BFCM. It shows a red background, a hand holding a clear plastic bag of jerky (called Pepper Beef Jerky) on the left. On the right, M&S Meat's logo with a buffalo is featured, along with a message that says "Come back!"

Direct Mail Is “Instrumental” in Driving Repeat Purchases for M&S Meats

PostPilot helped the 80-year-old premium jerky brand increase YoY holiday revenue by 110%.

trifold Cardalog that Gozney sent over Black Friday, featuring 6 panels. 3 panels in the interior feature high quality images of their hero products, the Dome, Roccbox, and Dome S1, along with product descriptions for each. The front of the Cardalog says "

Gozney Retargets & Converts Anonymous Website Visitors with Direct Mail

The outdoor pizza oven brand drove $100k+ in revenue and a 10X+ ROAS acquiring new customers with SiteMatch.

Promotional PostPilot Postcard for Mini Katana featuring two hands gripping ornate katana swords on either side. Central bold text reads "IT'S TIME TO BRING IT HOME," accompanied by smaller text promoting the perfect gift for sword enthusiasts, including d

Mini Katana Activates AWOL Email Subscribers with PostPilot 

The viral sword brand uses MailMatch to reach prospects who aren’t reading marketing emails. 

Handwritten-style birthday postcard from Plum Deluxe featuring a personal message addressed to a customer. The note thanks them for being part of the tea community and offers 15% off their next order with a discount code. The Plum Deluxe logo appears at th

Plum Deluxe Scales Handwritten Birthday Wishes with PostPilot

The community-powered gourmet tea brand adds a personal touch (at scale) for thousands of customers with PostPilot.

Direct mail postcard from Bones Coffee Company titled ‘Sip and Savor the Season.’ The design features five seasonal coffee bags labeled Apple Cider Donut, Pear-anormal Activity, Sweet Tater Swirl, Frankenbones, and Jacked ’O Lantern.

Bones Coffee Sees “Explosive” Results with Postcards

With their first two mailers, the company drove nearly $100k in sales and brought thousands of customers back into the fold.

Dr. Squatch spiderman product launch, powered by PostPilot. Says "Limited Edition Spidey Suds. Wth great briccs come great ingredients." Shows spider-man soap on left with a QR code and text on the right.

How Direct Mail Became an Essential Marketing Channel for Dr. Squatch

The rocketship CPG brand uses PostPilot for its concierge service and superior analytics.

Direct mail postcard from Poo~Pourri advertising a Black Friday sale. Multiple Poo~Pourri before-you-go toilet spray bottles are displayed alongside gift boxes wrapped with ribbons. Text promotes 30% off sitewide with free shipping and highlights seasonal

Pourri Smashed Its Black Friday Goals with PostPilot

Direct mail gave the home fragrances brand a 10% incremental revenue boost, outperforming every other channel.

graphic featuring a collage of colorful winpro postcards.

WINPRO Pet Uses Direct Mail to Reach All Its Customers

The pet supplements brand knows that direct mail connects when email can’t.

3D mockup of Misook's prospecting trifold Cardalog.

Cardalogs: A New Acquisition Channel for Misook

The women’s fashion brand tried prospecting with a faster, more flexible alternative to catalogs. It got a 3.4x ROAS.

Direct mail postcard from HexClad promoting a Black Friday sale. A close-up of a HexClad hybrid cookware pan with a hexagonal surface pattern appears beside text reading ‘Take Up to 40% Off,’ with the HexClad logo and website shown.

How HexClad Uses PostPilot to Convert Email Subscribers

The cookware brand’s direct mail campaign helped rack up $800k in sales from new customers.

graphic showing front and back of a wine by lamborghini postcard on a table.

Wine by Lamborghini Wins at Retention with PostPilot

Holiday campaigns and automated flows keep luxury customers coming back—generating more than 10x ROAS. 

graphic showing layers of caden lane postcards (same postcard is repeated).

Caden Lane Leans Into PostPilot for Cold Prospecting

Direct mail scored the stylish and fast-growing baby brand a 3.8x ROAS on a first-touchpoint campaign.

Rock City Lab Reactivates Subscribers with Postcards

The ecommerce marketing agency uses direct mail to bring lapsed subscribers back — at 7X the rate of organic reactivation.

Direct mail postcard from Laird Superfood featuring a lineup of superfood creamers, coffee, Instafuel, and protein products on an orange background. Text reads ‘Superfoods on the Mind?’ and promotes 20% off.

Laird Superfood Supercharges Retention With Postcards

Laird Hamilton’s plant-based food brand reengaged thousands of lapsed VIPs and saw 12x ROAS on a single campaign.

3D mockup of bright pink and light blue Obvi postcard

Obvi Drives Profits with Automated Postcard Campaigns

The rocketship supplements brand wanted to offset high ad costs and reach dormant customers. They scored 1000%+ ROIs.

BOOM! postcard showing 15% offer in black and pink text and a woman to the right.

Ezra Firestone's BOOM! Achieved a 2600% ROI with Postcards

Ecom legend Ezra Firestone knows how to retain customers. Get his direct mail playbook to drive retention and profits.

graphic showing 3d look at dr brandt postcard showing 3 women on the front over a light beige background.

Dr. Brandt Uses Postcards to Reach Lapsed Customers

The popular skincare brand relies on PostPilot to mitigate the high cost of online ads and email deliverability issues.

Grande Cosmetics Keeps VIPs Coming Back with Direct Mail

The cult beauty brand generated more than $276,000 from a single postcard campaign. Now, it’s going deeper.

Direct mail postcard from Beardbrand featuring two bearded men in a lifestyle photo. Text addresses the recipient by name and promotes a $20 discount

Beardbrand Wins Back “Unreachable” Customers with Easy, Effective Postcards

The OG mens grooming brand needed a way to reach and reactivate top customers who didn't engage with email. They got buyers back and achieved a 10X return.

3d representation of front/back of promix postcard showing supplement stack.

Promix Nutrition Uses Postcards to Get Into Customers’ Homes

Promix founder Albert Matheny was looking for more than ROI. He wanted to connect offline for stronger recognition, affinity, and credibility.

3d mockup of orbit baby postcard offering smooth travels and easy transfers for stroller.

Orbit Baby Uses Postcards to Acquire High-AOV Customers

With MailMatch™, the DTC stroller brand could send direct mail based just on the emails of high-intent shoppers.

Postcard from Bulletproof on an orange background showing supplements and protein products. Text reads ‘Stay Well. Stay Energized. Stay Bulletproof’

Bulletproof Re-Engages Customers with Direct Mail + Email

Bulletproof solved the one-time-buyer problem by converting massive second-purchases and new subscribers.

3D mockup of CYSM postcard showing 2x for $49 on their lotion.

CYSM Hyper-Personalizes 100+ Direct Mail Campaigns

The shapewear brand uses direct mail for holidays, retention, VIP rewards, and more to Drive >10X ROAS.

3D mockup of direct mail postcard showing truffle being shaved over pasta and the text "20% off just for you."

Urbani Truffles Wins Back High-Value Customers with Postcards

Urbani used postcards to win back valuable customers they couldn’t reach online, and how they’re now integrating direct mail across their marketing strategy.

ohmino postcard mockup showing black background and red supplement container and 20% off.

Oh!mino Uses Postcards to Get 60% of Customers Coming Back

CEO & founder Michael Maynard used automated direct mail to help lift reorder rates from 24% to 63%.

graphic of Ben Jabbawy with caption "Ecommerce Marketing School"

Privy CEO Ben Jabbawy on Driving 6% of Revenue with Postcards

Ben speaks with Jeremy Roberts, CMO of apparel brand Tradlands, on making direct mail a leading overall revenue channel.

Direct mail postcard from Morris 4x4 Center showing a modified Jeep off-road. Text asks if the recipient is done with their Jeep build and offers 10% off a next part with a personalized code.

Postcards Outperformed Email 18 to 1 for Morris 4X4

Studies show customers receiving direct mail marketing are more likely to spend more over time (higher LTV). Morris 4x4 put this theory to the test and the results were remarkable.

3d image of Direct mail postcard from ATH Organics featuring hands holding a cup. Text addresses the recipient by name and promotes 15% off their next order at athorganics.com.”

ATH Organics is Crushing ROI with Postcards

The supplements brand tests creative, offers, and personalization to optimize its direct mail campaigns.

Drag &
Scroll

5.0

Ready to increase your revenue?

Join thousands of ecommerce brands using PostPilot to acquire more customers & keep them coming back again (and again).

No contracts. No minimums.