Custom Poly Mailers
Lightweight and padded poly mailers, printed and biodegradable options.
For soft goods, a poly mailer beats a box: it weighs less, costs less to ship, and still protects the contents. We print them in your brand colors with a self-seal strip.
Choose padded mailers for fragile items, or recycled and compostable film if waste is a concern.
- Tear-resistant film with a peel-and-seal strip
- Padded (bubble-lined) option for fragile goods
- Recycled-content and compostable film available
- Full-color print across the whole mailer
“Mailers arrived in nine days with the inside print exactly as proofed. Our unboxing videos finally look like the brands we admire.”
“The free dieline saved us. Our first supplier wanted $400 for structural work; here it came with the quote, and the sample folded perfectly first try.”
Where a mailer beats a box
Apparel, textiles and anything soft that cannot break: that is poly mailer territory. The mailer weighs around a tenth of a comparable box, drops your dimensional-weight charges, and packs in a fraction of the space at the bench. For a clothing brand shipping thousands of orders, switching from cartons to printed mailers is often the single biggest packaging saving available.
The trade is protection. If the product can crease, snap or dent, it needs at least a padded mailer, and truly fragile goods still want a box.
Film specs that matter
Standard mailers run 2.5 mil (about 60 micron) co-extruded film: a grey opaque inner layer for privacy, white or printed outer for the brand. That thickness shrugs off conveyor abrasion and rain. Go to 3 mil for heavy or sharp-cornered contents like denim with metal hardware. The self-seal strip is a permanent hot-melt adhesive; once shut, opening it tears the bag, which is your tamper evidence.
We also print a second adhesive strip on request, so the same mailer survives one return trip. Customers reuse the bag to send the item back, and you save stocking separate returns packaging.
Print, and the sustainability question
Flexo printing covers the whole face edge to edge, up to full-bleed patterns in your brand colors; dark films with white or metallic ink photograph particularly well for social unboxings. On materials: recycled-content film (up to 100 percent PCR) is the practical green choice today, because it uses the existing film stream. Compostable mailers made from cornstarch blends exist and we supply them, but be straight with customers that most need industrial composting. Say which claim you are making and print the disposal instruction on the bag; vague leaf icons annoy the customers who care most.
Sizes and minimums
Stock sizes run from 6 x 9 in for accessories up to 24 x 24 in for bulky knitwear, with custom sizes at volume. Printed runs start at 500 units; unprinted stock ships from inventory.
