Custom Ecommerce Poly Mailers
Custom ecommerce poly mailers printed with your brand — self-seal, opaque, tear-resistant, with a second seal strip for returns — sized to your orders from 100. Proof and price the same working day.
The bag that replaced the box for anything soft
- Film
- Co-ex LDPE 60–80 micron; recycled-content; compostable; paper alternative
- Formats
- 6 × 9 to 19 × 24 in; custom sizes
- Seals
- Permanent self-seal; returns strip; tear strip
Get a price for Ecommerce Poly Mailers
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- Free dielineThe flat drawing comes with the quote, before you commit.
- Proof before pressNothing is printed until you have seen it laid on the dieline.
- Die kept for reordersTooling is paid once. Every reorder skips straight to press.
- Quoted in four marketsUS, UK, Canada and Australia, in the delivery currency.
Sizing to what you ship
Size to the folded item plus room to seal. A mailer that is too big folds over and looks careless; too small and the seal strains.
| 6 × 9 in | Accessories, a single small garment folded |
|---|---|
| 10 × 13 in | A tee, a pair of leggings; the most-used size |
| 12 × 15.5 in | A hoodie, two garments |
| 14.5 × 19 in | Bulk orders, bedding, a jacket |
| 19 × 24 in | Large soft goods |
Film, and the trade-offs
Our poly mailers in every size and film cover the padded and clear versions.
- Co-extruded LDPE, 60–80 micron — opaque, tear-resistant, the standard.
- Recycled-content film, 30–100% post-consumer — a slightly greyer white; no loss of strength.
- Compostable film — plant-based; composts industrially; less puncture resistance; dearer.
- Paper mailers — an alternative where the customer expects paper; heavier and less weatherproof.
Seals, returns and tamper evidence
A permanent self-seal strip closes the bag once and cannot be opened without tearing, which is the tamper evidence. A second strip below it — a returns strip — lets the customer reseal the same bag to send an item back, and it is the feature most fashion brands now specify. A tear strip along the top makes the opening clean rather than a scissors job.
Print on a mailer
Flexo in up to eight colors on the outside; a full-coverage print for a brand color, or a pattern, or a logo. The address panel is left clear or lightly tinted so a label sticks and scans. Inside print — a message seen as the bag is opened — is possible on a co-extruded film and costs little.
Leave the label panel white. Barcodes on a colored ground fail the carrier's scanner.
Quantities and the cost per parcel
Mailers are bought in hundreds and thousands; a hundred is a starter run, a thousand covers a small brand for a season. The cost per parcel is a few cents, and the postage saving over a box is usually the largest number on the page.
Ecommerce Poly Mailers — specification
The rows that are specific to this build first, then what applies to every job we run. Anything not listed is a question, not a limit — send the brief.
This build
- Film
- Co-ex LDPE 60–80 micron; recycled-content; compostable; paper alternative
- Formats
- 6 × 9 to 19 × 24 in; custom sizes
- Seals
- Permanent self-seal; returns strip; tear strip
- Flexo up to 8 colors; inside print; clear label panel
- Strength
- Tear- and puncture-resistant; opaque
- Recycling
- Soft plastic where collected; compostable film to named standard
- Minimum
- 100 bags
On every job
- Print process
- Flexo in up to ten colors on the outer film, or digital for short runs and changing artwork.
- Color
- A white underprint carries normal color on metallised or clear film. Without it, every color takes on what is beneath it.
- Tolerance
- Bag width plus or minus 2 mm, length plus or minus 3 mm. Film stretches, so a barcode is verified on a filled bag.
- Tooling
- Print plates or cylinders per design, kept. There is no cutting die — the bag is formed and sealed rather than cut.
- Food contact
- A food-grade sealing layer against the product, with the inks trapped between layers rather than on the food face.
- Sustainability
- Mono-material PE or PP where the shelf life allows, which recycles as a soft plastic. A foil laminate does not.
- Artwork
- Vector PDF or AI, 3 mm bleed, 4 mm safe area, fonts outlined. We check every file and send a proof before press.
- Dieline
- Supplied free with the quote, before you commit. Yours whether or not you order.
- Sample
- A plain unprinted sample at the finished size on request, for fit and construction.
- Reorders
- Skip the tooling and go straight to press at a lower unit price.
- Lead time
- Quoted with the price against your fill date rather than promised before we have seen the spec.
- Markets
- United States, United Kingdom, Canada, Australia — priced in the delivery currency, freight included.
Boards and films we build ecommerce poly mailers on
A flexible pack is a stack of films laminated together, and the middle layer is the barrier. The structure is chosen from the shelf life you need and what you want to be able to say about recycling.
PET / PE
A printable outer and a sealing inner. Moisture barrier, modest oxygen barrier. The everyday laminate for dry goods sold quickly.
2-ply, 70–110 micronPET / AL / PE
Aluminum foil in the middle: the strongest barrier against light, oxygen and moisture. Coffee, supplements, anything with a long shelf life.
3-ply, 90–130 micronMetallised PET
A vapour-deposited metal layer. Bright, lighter and cheaper than foil, with a weaker barrier. Most silver and gold bags are this.
2–3 plyMono-material PE
Every layer polyethylene, so the bag recycles as a soft plastic. Less barrier and a slightly softer hand; the sustainable choice where shelf life allows.
100–130 micronMono-material PP
Stiffer and clearer than PE, with better heat resistance. Suits a stand-up pouch that has to hold its shape on a shelf.
90–120 micronKraft-paper laminate
A paper outer over a film barrier. The natural look with a real barrier behind it; the paper takes only a matte, flat print.
Paper 60–80gsm + filmCompostable film
PLA and cellulose structures certified for industrial compost. Lower barrier, higher cost, and no home-compost claim unless the certificate says so.
60–90 micronLDPE mailer film
Co-extruded opaque film for shipping bags: tear- and puncture-resistant, weatherproof, and recyclable where soft plastics are collected.
60–80 micronNot sure which? Say what goes in it and where it is sold — the material follows from that. Our notes on recycled, recyclable and compostable cover which claims each stock can honestly carry.
- 01
Send what you have
A dimension, a photograph beside a ruler, or the product itself. No technical drawing needed — that part is ours.
- 02
We quote and draw
A price, a dieline and a date come back together. If a different build would suit the product better, that is in the reply too.
- 03
Approve the dieline
The flat drawing is yours to check: which panel is the front, where the folds fall, how deep the cavity really is.
- 04
Artwork on the dieline
You place your design on the flat we sent, or we place it for you, and you see a proof before anything goes to press.
- 05
A sample if you want one
A plain unprinted sample at the finished size shows fit and construction — the things a drawing cannot.
- 06
Cut, printed, shipped
The die is cut once and kept, so every reorder skips the tooling and goes straight to press at a lower unit price.
Format
Vector PDF or AI where possible. Raster artwork at 300dpi at final size, in CMYK.
Bleed
3 mm past every trim line, so a fraction of drift on the cutter never leaves a white edge.
Safe area
Keep type and anything important 4 mm inside the cut and away from every fold.
Color
Convert to CMYK before sending. Uncoated stock prints lighter; a spot color is the only exact match.
Fonts
Outline them or supply the files. A missing font substitutes silently and the proof will not match.
Barcodes
On a light, matte, unvarnished patch with the quiet zone clear — a code on gloss fails the scanner.
Not set up that way? Send it anyway — fixing a file is a short conversation, and we check every one before press. Our guide to preparing print files covers each point.
Film is finished in the lacquer and the ink, not with a laminate.
Matte lacquer
A soft, non-reflective face. Hides handling marks and the most-used finish on a premium pouch.
Gloss lacquer
Wet-looking color. Reads cheaper on some categories and exactly right on confectionery.
Spot matte on gloss
A matte shape on a gloss field, or the reverse. The film equivalent of spot UV.
Metallised effects
Print over the metal layer so a color picks up the shimmer, or lay white under it for a normal color.
Registered emboss
A raised texture pressed into the film. Rare, expensive, and unmistakable in the hand.
Kraft-paper face
A paper outer laminated to the barrier. Matte and flat by nature; no varnish needed.
Not sure which suits the shelf it sells from? Say where the product is sold and we suggest one — our notes on specialty finishes show them on real boxes.
Sizing a pouch by what goes in it, not by a bag size: ecommerce poly mailers
Film packs are specified by fill, not by dimensions. Two products of the same weight can need very different bags, because density decides volume — whole coffee beans take far more room than the same weight of powder.
- Fill weight and density
- Give us both, or send the product. We size from the volume it actually occupies, settled.
- Lay-flat width
- Half the circumference of the finished bag. It is the number a converter works to, and we calculate it from your product.
- Headspace
- Enough film above the fill to seal cleanly and for the bag to stand. Too little and the seal traps product; too much and the pack looks underfilled.
- Gusset
- Bottom gusset depth sets how the bag stands; side gussets add volume without width. Both are chosen from the shelf, not the fill.
- Seal width
- 5–8 mm. Wider on liquids and creams, which contaminate a seal, and on anything that will be posted.
- Sample fill
- A plain bag at the finished size, filled from your line, is the only reliable check before print.
Not sure your numbers are right? Send the product dimensions rather than the box dimensions and we work the box out — the full method is in our guide to measuring for a box.
Interactive · five steps · no sign-up
Spec your Ecommerce Poly Mailers
Pick a shape, type a size, choose a film and a finish. The preview on the left redraws as you go, and the spec lands with us exactly as you set it.
Frequently asked questions
Got a question about ecommerce poly mailers? The answers below cover what we get asked most. If yours is not here, send it with a brief, message us on WhatsApp, or call +1 503-461-4788 — we reply the same working day.
What size mailer do I need?
Size to the folded item plus room to seal. 10 × 13 inch is the most-used size for a single garment; we size larger for bundles.
Are poly mailers waterproof?
Yes, weatherproof enough for a doorstep in rain. The seal keeps water out.
Can the customer return an item in the same bag?
Yes, with a second returns seal strip below the first.
Is it tamper-evident?
Yes. The permanent seal cannot be opened without tearing the bag.
Can it be printed in full color?
Yes, up to eight colors flexo, full coverage or a logo, with the label panel left clear.
What is the minimum order?
100 bags.
Are they recyclable?
As soft plastic where collected. Recycled-content film is available with no loss of strength.
Do you have a compostable mailer?
Yes, a plant-based film that composts industrially, at a higher price and with less puncture resistance.
Can the inside be printed?
Yes, a message seen as the bag opens, on co-extruded film.
Do you make paper mailers too?
Yes, where a customer expects paper. They are heavier and less weatherproof than film.
Will a barcode scan on a printed bag?
Yes, if the label panel is left white. We keep it clear on the artwork.
Do you ship outside the US?
Yes, to the United States, United Kingdom, Canada and Australia, quoted in the delivery currency.
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