What are Poly Mailers? Everything You Need to Know Before You Ship

The way products are shipped has been revolutionized by online shopping. Consumers today demand prompt delivery, attractive packaging, and flawless products. Poly mailers can help with that! These flexible shipping bags are now among the most often used options for e-commerce companies, apparel retailers, subscription services, and even small handcrafted shops. 

If you are fed up with the bulk, the time spent packing, and the expensive postage, it's time to switch to the poly mailer. They are a lightweight and tear-resistant solution that caters to all the needs of online sellers. They offer a long-lasting barrier to products from moisture, UV rays, scratches, dust, and pressure without adding bulk to your package. 

It likely came in a poly mailer bag if you have ever gotten clothing, accessories, or soft products in a nice plastic envelope rather than a cardboard box.

However, what precisely are poly mailers, and why are companies adopting them so quickly? Let's take a closer look at everything. 

What Are Poly Mailers? 

A poly mailer is a lightweight, high-strength shipping envelope made from moisture-resistant polyethylene film. These bags are made using a newer technology than the traditional cardboard, making them incredibly easy to store. Also, they have a self-sealing adhesive strip, which does not require packing tape. 

Fortunately, mailers are made to be puncture-proof, stretchable, and able to conform to your products to reduce bulk and still create a professional, secure seal during transport. These mailers are commonly used for clothing, documents, beddings, phone cases, small fashion accessories, books, and non-fragile products. 

The best part? Using a slim mailer rather than a box can help businesses save a significant amount of dollars over time (because carriers sometimes base their pricing on package weight and size). 

Are These Eco-Friendly?

This depends on the material being used. Traditional poly mailers are plastic-based, but many manufacturers now offer:

• Recyclable mailers
• Reusable mailers
• Compostable mailer options
• Biodegradable blends

Sustainable packaging (be it a poly mailer bag or mailer boxes) is becoming more and more important to environmentally concerned consumers. Businesses that use greener delivery methods frequently see an increase in consumer loyalty and perception. However, durability is also important. Sometimes, a sturdy reusable mailer produces less trash than flimsy packaging that needs to be replaced.

Pros To Consider

These are the main benefits to take into account when using poly mailers for your shipping requirements. They demonstrate why they are a creative, practical, and economical packing option.

Weather- and Tear-Resistant

Designed to be extra resilient and long-lasting, these mailers serve as a protective barrier against moisture, dirt, UV rays, pressure, scratches, and heat during the shipping process. Yes, it doesn't tear easily or lose its shape when exposed to water (rain or accidental spills).

Lightweight

Brands may drastically reduce shipping costs because these bags weigh relatively little. Particularly helpful for high-volume eCommerce enterprises are lightweight shipping bags. Over thousands of shipments, even a few ounces off each package can result in significant savings. 

Read More: Understanding Cardboard Box Weight (Formulas, Examples, & Calculator)

Fast Assembly 

All sizes are packed in seconds with built-in “peel-and-seal” adhesive strips. Say goodbye to tape dispenser issues! Packing teams can process orders more quickly and increase workflow productivity since they are simple to access and quick to use. Indeed, it is a huge advantage during sales seasons and high-order periods.

Efficient Storage

For companies looking to save storage space without compromising package performance, poly mailers are a wise option. The thin, flexible design of poly mailers requires a lot less storage and can be stacked in a small space. It also helps businesses to maintain thousands of pieces organized without packing warehouses to capacity. After all, cardboard mailer boxes will demand sufficient space.

Brand Customization

Besides being simple black poly mailer bags or white, you can have them printed with your branding elements, compliance details, sustainable icons, or product details. You can even choose from matte or gloss finishing, metallic accents, and more. Feel like giving a sneak peek? Add a window patch!

Read More: What is Window Patching? A Deep Dive into the Machinery and Process

Versatility

They are the standard for apparel and soft goods, but can also be used for shipping documents and accessories, as well as for pre-packaged goods that do not need the structural support of a box.

Poly Mailer Bag Sizes

Choosing the wrong size can lead to a waste of material or the product not fitting accurately. Well, a professional and cost-efficient shipment depends on obtaining the right poly mailer dimensions. 

Take your product dimensions when it is folded or compressed as much as possible. For easy insertion and sealing, add approximately 2″ width and length. 

The following is a brief reference sheet for the most popular sizes of poly mailer bags:

Bonus: If you're looking for an e-commerce purpose, poly mailer 10×13 is the most popular size. 

Different Types of Poly Mailers

There are many different types of mailers. Let's have a look at each of these:

Standard Poly Mailers

The actual workhorse of e-commerce shipping, these basic poly mailers are extremely reliable and a low-priced option. They are manufactured using high-quality polyethylene and are resistant to tears, rough handling, and water. Use them to pack soft but non-fragile items, such as clothing, accessories, documents, brochures, and catalogs. It can work brilliantly for subscription packaging.

Gray Mailes

If you’ve ever wondered what is a gray mailer, it’s just a standard poly mailer in a neutral gray colour, which is a common colour used for fashion and lifestyle brands for its minimalistic and sophisticated look. It is often paired with a black interior layer for privacy and durability.

Bubble Poly Mailers

Poly bubble mailers come in handy when your products require a little extra care during transit. These include a layer of built-in bubble wrap lining that's fused to the inner wall, and cushioning the items. They are great for lightweight, fragile items like jewelry, electronics, cosmetics, lamps, or any other delicate accessories. 

Eco-Friendly/Compostable Mailers

A compostable mailer is able to decompose naturally without leaving any harmful microplastics behind. These are made from plant-based and/or certified compostable material, according to industrial or home composting standards. Besides, they're perfect for companies looking to be environmentally conscious and reduce their impact on the planet while maintaining protection and durability. 

Kraft Poly Mailers

Just like Kraft mailer boxes, there are Kraft poly mailers. A perfect solution with a natural kraft paper exterior and a moisture-resistant polyethylene liner! The paper exterior layer provides a smooth and natural appearance, ideal for artisan or organic/health-oriented brands. At the same time, the poly lining ensures you have trouble-free products being protected from wetness and spills. 

Tyvek Poly Mailers

Denser woven polyethylene fibers are used to make Tyvek poly mailers, which are designed to be more resilient than other varieties. They are an affordable, long-lasting, and water-resistant choice for carrying important paperwork and photos. Tyvek is a good alternative if you're searching for durable packaging.

Co-Ex Poly Mailers

There are some products that require more than one-layer bag. Co-extruded (Co-Ex) poly mailers are made of several layers of plastic bonded together to be much stronger and more puncture-resistant than others. They basically serve as heavy-duty plastic bags and are able to carry heavier, bulkier, and denser soft goods without splitting or tearing. 

Custom Printed Mailers

There are many first impressions your customer will have with your brand, and it's your packaging that makes the first impression. Printed poly mailers are a great option to show off your logo, brand colors, taglines, and artwork straight on the surface. Each delivery is displayed as a mini billboard and is an unboxing event that will lead to repeat orders and social sharing. You can also add stickers or labels as needed.

Clear poly mailer bags 

Clear poly mailer bags are also available, which can be beneficial for the visibility of products or mailing documents. They are often used for transporting retail goods that benefit from a conspicuous presentation or for inventory organization.

How to Choose the Right Poly Mailer

Before selecting a mailer, consider:

• Product Weight: For shipment, heavy goods require larger mailers or sturdy plastic bags.
• Product Dimensions: Always choose the appropriate poly mailer dimensions to match the product size.
• Branding: For a luxurious look, upscale brands frequently select black poly mailer bags.
• Sustainability: Compostable envelope packaging is typically preferred by environmentally conscious businesses.
• Shipment Conditions: Mailers that are cushioned or stronger may be needed for long-distance shipment.

Cons | Disadvantages of Poly Mailers 

1. Glass and other easily breakable items cannot be handled.
2. Unless it's a flat item like soft clothing, poly mailers are not the greatest choice for mailing numerous goods at once.
3. The packaging may sustain damage during processing at the post office or during transit if the poly mailer is improperly filled or if you used the incorrect kind of poly mailer for your product.

Wrap Up

Poly mailers are lighter than cardboard boxes, easier to pack, less expensive to ship, and can be used in endless ways for product safety.

For today's fast-paced eCommerce settings, they are highly adjustable, fashionable, affordable, and useful. Every brand and product type has a mailer style, whether you choose gray mailers for expert dispatching, clear poly mailer bags for exposure, or biodegradable mailer alternatives for sustainability. 

Whether you need a bubble poly mailer or mailer boxes, we bring a complete selection. Custom Product Packaging lets you design the best custom packaging - be it bags, pouches, boxes, bubble mailers, and paper bags - for your business. Our packaging experts will be here to assist you and offer you a free instant quote. Shoot an email or call us directly: +1 (888) 511-0592.