Custom Economy Poly Mailers
Custom economy poly mailers from 100 — plain white or gray co-extruded film, a lighter gauge, a self-seal strip and at most a one-color logo, made for sellers who ship a lot of soft goods and count the cost of every bag.
The cheapest bag that still gets a parcel there
- Film
- Co-ex LDPE 50–60 micron, white outside and gray inside or plain gray; opaque
- Closure
- Permanent self-seal strip
- Plain, or one-color logo in one position
Order online
Order economy poly mailers
Starting from $0.75 per unit
Printed to your artwork or plain, sold in runs of 100 up to 5,000 units per product online. Freight to the US, UK, Canada and Australia is inside the price.
How an online order runs
- Add the units you needThen check out with your delivery address. Add other products to the same order on the way.
- A digital proof comes backLaid on the dieline, before anything prints. Change it as often as you need.
- Pay once you approve itPay by PayPal invoice or bank transfer after you approve your digital proof, or cash on delivery in the US and Canada.
- We make it and ship it deliveredYour delivery date is confirmed with the proof, against the spec and your fill date. Freight and customs are handled on the way to you.
Another size, board or finish, or more than 5,000 units? Send the spec for a price instead. Freight by market and our terms cover delivery and remakes.
Get a price for Economy 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.
Where the savings come from
Each line on its own is a small saving. Together they bring the bag close to the cost of the film itself, which is what makes an economy mailer worth having.
| Film gauge | 50–60 micron instead of 75–80; enough for soft goods |
|---|---|
| Color | Stock white-outside, gray-inside or plain gray film; no custom pigment |
| None, or a one-color logo in one position | |
| Strips | One permanent self-seal; no returns strip, no tear strip |
| Sizes | Standard sizes off existing tooling rather than custom cuts |
What an economy mailer is right for
- Folded clothing, socks, scarves and soft accessories that cannot be crushed.
- Refill packs, wipes, cloth face covers and other flat soft goods.
- Printed matter in a sleeve, such as a catalog or a calendar on a card.
- Second-hand clothing and marketplace sellers shipping single items.
- Inner bags inside a carton, where nobody sees the outside.
Where to spend a little more
A thinner film is fine for cloth and poor for corners. Anything boxed, anything with an edge such as a book or a phone case, or a parcel heavier than about a kilogram is better in a standard gauge or a padded mailer. Brands that want the bag to sell the brand on the doorstep usually move up to a fully printed bag; our fully branded poly mailers in full color are the next step up.
If you are not sure the light gauge will hold, ask for samples of both and pack a real order in each.
A one-color logo, placed once
An economy mailer can still carry the store name. A single ink, usually black on white or white on gray, printed in one place on the front, adds very little to the price and tells the customer who the parcel is from. The shipping label still goes on a plain area, so we keep the logo to one corner or the flap and leave the rest clear.
Buying for volume without storing a warehouse
Economy mailers are light and flat, a few hundred to a carton, so they take little room. Most sellers order two or three sizes that cover their whole range rather than one size per product, and reorder the size that runs out first. The 100 minimum is per size, so a first order can test a mix. See the full range of poly mailers and sizes for the other builds.
Economy 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 50–60 micron, white outside and gray inside or plain gray; opaque
- Closure
- Permanent self-seal strip
- Plain, or one-color logo in one position
- Sizes
- Standard sizes, from 6 x 9 in to 19 x 24 in
- Suited to
- Clothing and soft goods; not for sharp-edged or heavy items
- Minimum
- 100 mailers per size
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 metalized 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 economy 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 micronMetalized PET
A vapor-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.
Metalized 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: economy 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 Economy 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 economy 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 makes an economy poly mailer cheaper?
A lighter film gauge, stock white or gray film, little or no print, one seal strip and standard sizes. Each saves a little and together they bring the bag close to film cost.
Is an economy poly mailer strong enough for clothing?
Yes. A 50–60 micron co-extruded film is strong enough for folded clothing and other soft goods.
What should not go in an economy poly mailer?
Boxed items, books, anything with a hard corner and heavier parcels. They are better in a standard gauge or a padded mailer.
Can an economy poly mailer be printed with a logo?
Yes. A one-color logo in one position, such as a corner or the flap, adds very little to the price.
Are economy poly mailers see-through?
No. White-outside, gray-inside film is opaque, so the contents cannot be seen through the bag.
Do economy poly mailers have a returns strip?
No, they keep one permanent self-seal strip to save cost. Choose a standard mailer if your customers return orders often.
What sizes do economy poly mailers come in?
Standard sizes from 6 x 9 in up to 19 x 24 in. Most sellers cover their range with two or three sizes.
Can I mix sizes in an economy poly mailer order?
Yes. The minimum is 100 per size, so a first order can include a few sizes to see which ones you use most.
Will a thin poly mailer tear in the post?
It holds well for soft contents. Tears usually come from sharp corners inside the bag, which is why boxed items should go in a heavier film.
Can economy poly mailers be used as inner bags?
Yes. They are often used inside cartons to keep garments clean, where nobody sees the outside of the bag.
How do I know if the economy gauge will be enough?
Ask for samples of the economy and standard gauges and ship a real order in each before you choose.
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