Custom Poly Mailers
A poly mailer weighs a few grams, costs a fraction of a box, and offers no protection at all. For soft goods that is exactly right, and the mistake almost everyone makes is using one for something that needed a box.
Get a price for 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.
- 4styles in this range, each with its own page and price
- 100unit minimum on every style, printed or plain
- 4markets quoted in the delivery currency
- ±1mmcutting tolerance on folding board, checked on a sample
4 styles in this range
Styles we make in this range
Every one below is written up, priced and dielined. Tap a style to see how it is built.
01See the build →10x13 Poly Mailers
Custom 10 × 13 inch poly mailers
02See the build →Branded Poly Mailers
A mailer is handled by a courier, left with a neighbour, carried through a hallway and opened at a kitchen…
03See the build →Bubble Wrap Roll for Packing
Custom bubble wrap rolls in the width and bubble size your packing bench uses, perforated to tear by hand,…
04See the build →Ecommerce Poly Mailers
Custom ecommerce poly mailers printed with your brand
Side by side
Which poly mailers style fits
| Style | Board | Build | Minimum | |
|---|---|---|---|---|
| 10x13 Poly Mailers | Co-ex LDPE 60–80 micron; recycled-content option | 10 × 13 in; usable 9.5 × 12 in | 100 bags | Open → |
| Branded Poly Mailers | Recycled-content or virgin polythene; compostable on request | See the page | 100 mailers | Open → |
| Bubble Wrap Roll for Packing | LDPE, 10 mm or 25–30 mm bubble; anti-static; 30–50% recycled content option | 300–1,500 mm widths; 50–100 m rolls; perforated every 300 mm | 100 rolls | Open → |
| Ecommerce Poly Mailers | Co-ex LDPE 60–80 micron; recycled-content; compostable; paper alternative | 6 × 9 to 19 × 24 in; custom sizes | 100 bags | Open → |
What belongs in one, and what does not
Bubble-lined mailers sit between the two: enough cushioning for a small solid object, still far lighter than a box. They are also much harder to recycle, because the bubble layer and the outer are different materials.
| Apparel and textiles | Ideal — soft, unbreakable, and the weight saving is real |
|---|---|
| Books and stationery | Corners get bent; use a book wrap instead |
| Anything rigid with edges | The edges wear through the film in transit |
| Anything fragile | No — a mailer is a bag, not protection |
| Anything that must not bend | No, unless a stiffener goes in with it |
Weight is the entire commercial argument
Carriers price on weight and volume together. Replacing a small box with a mailer removes both the board and the air around the product, and on a light item that can move an entire product line into a cheaper band.
Across a season that saving is usually larger than the whole packaging spend — the thresholds are set out in our guide to how carriers charge by volume.
Check the carrier's thickness limit as well as its weight limit. A stuffed mailer can exceed a letterbox depth even while weighing very little.
The recyclability question, answered honestly
The defensible position for most brands is recycled-content polythene with a clear line on the pack telling the customer where it can actually go. Claiming more than that invites the complaint.
- Standard poly mailers are polythene and are recyclable — but almost never in a curbside bin.
- Recycled-content film is widely available and performs identically.
- Bubble-lined mailers combine two materials and are effectively not recyclable.
- Paper mailers recycle in a normal stream and tear far more easily.
- Compostable films need a stream that most customers do not have.
Sizes, and why three is usually enough
Mailers are forgiving about fit in a way boxes are not — a slightly large mailer folds down around its contents. That means a small range of sizes covers a wide catalog, which keeps unit prices down and the packing bench simple.
The common ladder is roughly 250 × 350 mm for single garments, 350 × 450 mm for multiples, and 450 × 550 mm for bulky items. Most apparel businesses need nothing else.
Returns, printing and the second seal
A second adhesive strip below the first lets the customer reseal the same mailer and send it back. In apparel, where a large share of orders are returned, that removes a whole second pack from the operation.
Print is cheap on film and the whole surface is available. A mailer is seen by the courier, the neighbour who takes it in, and the customer — which is more attention than most brands assume a bag gets.
Across the range
What every poly mailers job runs on
Boards
- Natural kraft
- White SBS
- E and B flute
- Wrapped grayboard
- Food-grade board
- Recycled content
Chosen from what goes in the box and how far it travels. Our notes on recyclable and compostable stocks say which claims each board can carry.
Finishes
- Matte
- Gloss
- Soft-touch
- Foil
- Emboss
- Spot UV
- Kraft
- Textured
Each one is a decision about light on a shelf — the specialty finishes range shows them on real boxes.
Artwork
- Vector PDF or AI, fonts outlined
- 3 mm bleed, 4 mm safe area
- CMYK; a spot color where a match must hold
- Proof on the dieline before press
Files not set up that way are fine — see the guide to preparing print files.
Interactive · five steps · no sign-up
Spec your 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 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.
Are poly mailers recyclable?
The plain polythene ones are, but rarely curbside. Bubble-lined ones combine two materials and effectively are not.
Can I post books in one?
You can, and the corners arrive bent. A book wrap costs a little more and protects the edges.
How many sizes do I need?
Three covers most apparel catalogs. Mailers fold down around their contents, so fit is forgiving.
Is a return strip worth it?
In apparel, almost always. It removes a second pack from every return.
What is the minimum order?
100 mailers, any size.
Will a mailer save on postage?
Often more than the mailer costs. Removing the board and the air around a light item can move a whole line into a cheaper band.
Are poly mailers recyclable?
The plain polythene ones are, but rarely curbside. Bubble-lined ones combine two materials and effectively are not.
Can I post books in one?
You can, and the corners arrive bent. A book wrap costs a little more and protects the edges.
How many sizes do I need?
Three covers most apparel catalogs. Mailers fold down around their contents, so fit is far more forgiving than a box.
Is a return strip worth it?
In apparel, almost always. It removes a second pack from every return.
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