Custom Poly Mailers - Lightweight Branded Poly Mailers

Waterproof, Cost-Effective Shipping Solutions for E-Commerce

Ship smarter with Custom Poly Mailers – the lightweight, waterproof alternative to boxes that reduces shipping costs while building brand recognition. Perfect for apparel, textiles, accessories, and non-fragile items, our branded poly mailers protect products during transit while putting your brand front and center when packages arrive. Custom printing, eco-friendly options, and competitive pricing for growing e-commerce businesses.

Custom Poly Mailers for Cost-Effective E-Commerce Shipping

Reduce shipping costs without sacrificing brand impact. Custom shipping bags (poly mailers) offer the perfect solution for e-commerce businesses shipping lightweight products – combining waterproof protection, tear-resistant durability, and full-color branding at a fraction of the cost and weight of corrugated boxes.

Unlike plain poly mailers that arrive looking generic and disposable, custom branded poly mailers turn every delivery into a marketing opportunity. Your logo, colors, and design are the first thing customers see when their order arrives, creating brand recognition that builds over time.

For apparel brands, fashion accessories, textile products, and other soft goods, poly mailers provide ideal shipping protection while dramatically reducing dimensional weight charges – savings that add up quickly when shipping hundreds or thousands of orders monthly.

Manufactured in China with premium materials and shipped directly to your fulfillment center, our custom poly mailers deliver professional branding at competitive wholesale pricing accessible to startups and established brands alike.

The Poly Mailer Advantage for Online Retailers

Poly mailers weigh 80-90% less than equivalent corrugated boxes, dramatically reducing shipping costs through lower dimensional weight charges. For a business shipping 1,000 orders monthly, switching from boxes to poly mailers can save $500-1,500 per month in shipping fees alone.

No assembly required – simply insert product, peel adhesive strip, seal, and ship. Poly mailers streamline fulfillment operations, reducing labor time per order by 30-50% compared to box packing, taping, and sealing.

Poly Mailer Styles for Different E-Commerce Needs

From standard poly mailers to eco-friendly compostable options, choose the right shipping bag for your products and brand values.

Standard Poly Mailers

Classic poly mailer with durable polyethylene and self-sealing adhesive. Most economical option for high-volume shipping.

From $0.15/mailer

MOQ: 500 units

Perfect for: Apparel, accessories, textiles, soft goods

Bubble Poly Mailers

Built-in bubble wrap padding for extra product protection. Lightweight shipping with cushioned protection.

From $0.30/mailer

MOQ: 500 units

Perfect for: Electronics accessories, cosmetics, small tech items

Compostable Mailers

Plant-based materials that break down in commercial composting. Certified biodegradable for eco-conscious brands.

From $0.40/mailer

MOQ: 1,000 units

Perfect for: Sustainable brands, organic products, green businesses

Custom Sizes

Any size from 4×6" to 19×24". Perfect-sizing reduces waste and minimizes dimensional weight shipping costs.

Custom Quote

MOQ: 1,000 units

Perfect for: Unique product dimensions, shipping optimization

Our Custom Custom Poly Mailers

Browse our poly mailer options designed for cost-effective e-commerce shipping. All shipping bags can be fully customized with your branding and come in eco-friendly options.

Standard Poly Mailer

Waterproof, tear-resistant, full-color printing

From $0.15/unit

Bubble Poly Mailer

Built-in bubble padding for extra protection

From $0.30/unit

Compostable Mailer

Plant-based, certified biodegradable

From $0.40/unit

Custom Poly Mailer Design & Printing Options

Explore all available customization options to create the perfect branded shipping bags for your e-commerce business.

Material Options

Choose from durable, eco-friendly, or recycled materials based on your brand values and budget.

Standard LDPE (Low-Density Polyethylene)

  • Most economical option
  • Durable and waterproof
  • Opaque white or silver exterior
  • Recyclable (#4 plastic)

Co-Extruded LDPE

  • Multi-layer construction
  • Extra tear resistance
  • Premium durability
  • Slightly higher cost

Compostable PLA/PBAT

  • Plant-based materials (corn starch, cassava)
  • Certified compostable (commercial facilities)
  • Similar performance to traditional poly
  • Premium eco-friendly option
  • 30-40% higher cost

Recycled Content Options

  • 25-50% post-consumer recycled content
  • Maintains durability and performance
  • Lower environmental impact
  • Moderate price premium

Printing & Design

Full-color printing with unlimited design possibilities to showcase your brand.

Full-Color Printing (CMYK)

Unlimited colors and complexity. Photos, gradients, complex designs. High-resolution graphics. Both sides printable.

Print Coverage Options

Front only (most economical), Front + back (full branding), Inside message printing (premium touch).

Design Elements

Logo and branding, Patterns or backgrounds, Taglines and messaging, Social media handles, QR codes for engagement, Website URL.

Print Quality

High-resolution graphics (300 DPI), Vibrant color reproduction, Waterproof inks, Fade-resistant.

Size Customization

Standard sizes ready to order, or fully custom dimensions for perfect-fit packaging.

6×9"

Small items, jewelry, cosmetics

10×13"

T-shirts, small apparel

12×15.5"

General apparel, multiple items

14×19"

Larger clothing, jackets

19×24"

Bedding, large apparel, multi-item ordersGeneral apparel, multiple items

Custom Sizes

Any dimension from 4″ to 24″ width/length

Gusset Options: Flat (standard) for thin items, or Side gusset (2-4″) to accommodate thicker products.

Additional Features

Enhance your poly mailers with functional features for better customer experience.

Self-Sealing Adhesive

Permanent adhesive strip, tamper-evident closure, no tape needed, fast secure sealing.

Tear Strip

Easy-open tear notch for customer convenience. Professional touch.

Bubble Wrap Lining

Integrated bubble cushioning for extra protection. Lightweight padding for fragile items.

Second Adhesive Strip

Allows customer returns in same mailer. Convenience feature for return-friendly packaging.

When to Choose Poly Mailers Over Boxes

Feature Poly Mailers Mailer Boxes Standard Boxes
Weight
0.5-2 oz
2-6 oz
4-12 oz
Shipping Cost
Lowest
Medium
Highest
Protection
Good (soft goods)
Excellent
Excellent
Waterproof
Yes
No
No
Storage Space
Minimal (flat)
Ships flat
Ships flat
Assembly Time
None (peel & seal)
5-10 seconds
30+ seconds
Perceived Value
Economy/efficient
Premium
Standard
Cost per Unit
$0.15-0.50
$0.50-1.50
$0.30-0.80
Best For
Apparel, soft goods
General e-commerce
Heavy/fragile items

Choose Poly Mailers When:

Consider Boxes When:

Perfect for These E-Commerce Categories

Apparel & Fashion Brands

Poly mailers are the standard for clothing e-commerce. T-shirts, dresses, and activewear ship perfectly, arriving wrinkle-free and protected. Save $1.50-3.00 per shipment vs boxes.

Dropshipping Businesses

Lowest cost packaging option that's easy for suppliers to use. Branded packaging without inventory overhead. Perfect for AliExpress and POD businesses.

Beauty & Cosmetics

Non-fragile beauty products in plastic bottles and tubes ship safely. Padded poly mailers add extra protection for moderate-value items.

Accessories & Small Items

Phone cases, jewelry in protective packaging, scarves, hats, and socks fit perfectly with minimal dimensional weight charges.

Subscription Box Services

Monthly soft goods subscriptions benefit from poly mailer cost savings. Seasonal designs keep packaging fresh month after month.

Print-on-Demand Businesses

POD t-shirts and hoodies from Printful, Printify ship perfectly in branded poly mailers. Professional presentation on thin margins.

The Poly Mailer Advantage for Online Retailers

Significant Cost Savings

Poly mailers weigh 80-90% less than equivalent corrugated boxes, dramatically reducing shipping costs through lower dimensional weight charges. For a business shipping 1,000 orders monthly, switching from boxes to poly mailers can save $500-1,500 per month in shipping fees alone.

Waterproof Protection

Unlike cardboard boxes that deteriorate in rain, poly mailers are completely waterproof. Products arrive dry and protected even in harsh weather conditions - critical for maintaining customer satisfaction and reducing damage-related returns.

Space-Efficient Storage

Poly mailers ship and store flat, taking up 90% less warehouse space than boxes. This is especially valuable for small businesses, dropshippers, and fulfillment operations with limited storage capacity.

Fast Fulfillment

No assembly required - simply insert product, peel adhesive strip, seal, and ship. Poly mailers streamline fulfillment operations, reducing labor time per order by 30-50% compared to box packing, taping, and sealing.

Tear-Resistant Durability

Made from co-extruded polyethylene film, poly mailers resist tears and punctures during shipping and handling. They protect contents while remaining lightweight - the ideal combination for cost-effective shipping.

Custom Branding Opportunities

Full-color printing transforms plain poly mailers into branded packaging that builds recognition and encourages repeat business. Studies show 67% of consumers are more likely to repurchase from brands with memorable packaging.

Eco-Friendly Options Available

While traditional poly mailers are plastic, we offer biodegradable and compostable alternatives made from plant-based materials that break down naturally, allowing eco-conscious brands to use poly mailers sustainably.

Poly Mailer Specifications & Ordering Details

Materials & Thickness
  • Standard: 2.5 mil (63 microns) – suitable for most applications
  • Heavy-duty: 3.0 mil (76 microns) – extra durability
  • Premium: 3.5 mil (89 microns) – maximum protection
  • Co-extruded polyethylene film, multi-layer construction
  • Waterproof: 100% moisture barrier
  • Temperature range: -40°F to 180°F
  • Small 6×9″: Jewelry, cosmetics, phone cases – $0.15-0.25/unit
  • Medium 10×13″: T-shirts, small apparel, beauty – $0.18-0.30/unit
  • Standard 12×15.5″: General apparel, multiple items – $0.22-0.35/unit
  • Large 14×19″: Jackets, larger clothing – $0.28-0.45/unit
  • Extra Large 19×24″: Bedding, large apparel – $0.35-0.60/unit
  • Custom sizes available from 4″ to 24″ width/length
  • Full-color CMYK printing (unlimited colors)
  • Pantone color matching available
  • Front only or front + back printing
  • Inside message printing (premium option)
  • QR codes, social handles, website URLs
  • High-resolution 300 DPI graphics
  • Standard MOQ: 500 units
  • Custom sizes: 1,000 units minimum
  • Compostable mailers: 1,000 units minimum
  • Reorders: 250 units minimum
  • Production: 3-4 weeks
  • Total timeline: 5-7 weeks typical

Frequently Asked Questions About Custom Poly Mailers

Are poly mailers cheaper than boxes for shipping?

Yes, significantly cheaper in most cases:

Product Cost Comparison (per unit):

  • Poly mailer: $0.15-0.50
  • Mailer box: $0.50-1.50
  • Product savings: $0.35-1.00 per shipment


Shipping Cost Comparison (typical apparel):

  • Poly mailer (2 oz): $4.50-6.00 USPS First Class
  • Mailer box (6 oz): $6.00-8.00 USPS First Class/Priority
  • Shipping savings: $1.50-2.00 per shipment


Total Savings Per Order:
$1.85-3.00

Annual Savings (1,000 orders/month): $22,000-36,000

For soft goods and non-fragile items, poly mailers almost always reduce total costs significantly.

Yes, excellent protection for appropriate product types:

What Poly Mailers Protect Against:

  • ✓ Water/moisture (100% waterproof)
  • ✓ Dirt and dust
  • ✓ Light impacts and handling
  • ✓ Compression
  • ✓ Tearing and punctures


Products Well-Protected:

  • Apparel (shirts, pants, dresses, activewear)
  • Soft accessories (scarves, hats, bags)
  • Non-fragile beauty products
  • Phone cases and soft tech accessories


When to Use Bubble Poly Mailers:

  • Moderately fragile items
  • Beauty products with glass components
  • Items valued $50-200+


When to Use Boxes:

  • Fragile items (glass, ceramics)
  • High-value luxury items ($200+)
  • Items that could be crushed

Traditional poly mailers are plastic (#4 LDPE), but we offer eco-friendly alternatives:

Eco-Friendly Options:

1. Compostable Poly Mailers:

  • Made from plant-based materials (PLA, PBAT, corn starch)
  • Certified compostable (ASTM D6400, EN 13432)
  • Break down in 90-180 days in commercial facilities
  • Pricing: +40-60% vs standard


2. Recycled Content Poly Mailers:

  • 25-50% post-consumer recycled plastic
  • Maintains waterproof and tear-resistant properties
  • Pricing: +15-25% vs standard


3. Recyclable with Clear Labeling:

  • Standard LDPE with recycling instructions
  • “How to recycle” printed on mailer
  • No additional cost


Environmental Note:
Poly mailers actually have lower overall impact than boxes in many cases due to 80-90% less material and lighter shipping weight.

Minimum order quantities:

Standard Poly Mailers:

  • Stock sizes with custom printing: 500 units
  • Custom sizes: 1,000 units
  • Reorders (same design): 250 units

Compostable Mailers:

  • Minimum: 1,000 units

What 500 Units Represents:

  • Small business (20 orders/week): 6 months supply
  • Medium business (100 orders/week): 1.5 months supply
  • Large business (500 orders/week): 1 week supply

Volume Discounts:

  • 500 units: Base price
  • 1,000 units: ~10% discount
  • 2,500 units: ~20% discount
  • 5,000+ units: ~30% discount

Complete timeline from order to delivery:

Design Phase: 2-3 business days
Sample Production (Optional): 7-10 days
Full Production: 3-4 weeks
Shipping: 1-3 weeks (sea) or 5-7 days (air)

Total Standard Timeline: 5-7 weeks

Rush Production Available:

  • 2-week production
  • Air freight shipping (1 week)
  • Total rush timeline: 3-4 weeks
  • Additional 20-30% fee

Reorders: 3-6 weeks (no design approval needed)

Yes! We can include various custom elements:

QR Codes Link To:

  • Review requests
  • Social media profiles
  • Product care instructions
  • Exclusive discounts
  • Loyalty programs
  • Return portals

QR Code Specs:

  • Minimum size: 0.75″ × 0.75″ for reliable scanning
  • No additional cost for inclusion
  • We can generate QR codes or use yours

Other Custom Elements:

  • Your logo (any size)
  • Brand colors (Pantone matching)
  • Taglines and messaging
  • Social media handles
  • Website URL
  • Hashtags for campaigns

Key differences:

Material:

  • Poly Mailers: Flexible polyethylene plastic, waterproof
  • Mailer Boxes: Rigid corrugated cardboard, not waterproof

Weight & Cost:

  • Poly Mailers: 0.5-2 oz, $0.15-0.50/unit
  • Mailer Boxes: 2-6 oz, $0.50-1.50/unit
  • Shipping savings: $1-3 per shipment with poly

Protection:

  • Poly Mailers: Great for soft, flexible items
  • Mailer Boxes: Great for all products including fragile

Presentation:

  • Poly Mailers: Economy/efficient positioning
  • Mailer Boxes: Premium unboxing experience

Best Use Cases:

  • Poly Mailers: Apparel, fashion, soft accessories
  • Mailer Boxes: General e-commerce, premium brands

Yes, we strongly recommend sampling:

Physical Production Sample:

  • Exact replica of your final poly mailer
  • Includes your design, size, printing, materials
  • Production time: 7-10 business days
  • Sample cost: $50-100 (credited to full order)

What Sample Includes:

  • 1-3 physical poly mailers with your exact design
  • Actual size, materials, and printing
  • Allows hands-on testing

Sample Testing Checklist:

  • □ Size fits your products properly
  • □ Adhesive closure seals securely
  • □ Printing quality meets expectations
  • □ Colors match your brand
  • □ Material thickness appropriate
  • □ Waterproof performance (test with water)

Yes! Multiple sustainable alternatives:

1. Certified Compostable Poly Mailers:

  • Made from PLA, PBAT, corn starch
  • ASTM D6400, EN 13432 certified
  • Break down in 90-180 days
  • Pricing: +40-60% premium
  • MOQ: 1,000 units

2. Recycled Content Poly Mailers:

  • 25-50% post-consumer recycled LDPE
  • Maintains all protective properties
  • Pricing: +15-25% premium
  • MOQ: 500 units

3. Standard Recyclable with Messaging:

  • LDPE with printed recycling instructions
  • QR code to recycling locator
  • No additional cost
  • MOQ: 500 units

Recommendation:

  • Premium eco brands: Compostable
  • Budget eco brands: Recycled content
  • All brands: Recycling education on packaging

Sizing process:

Step 1: Measure Your Products

  • Length × Width × Height
  • Include any existing packaging
  • Measure when folded/compressed

Step 2: Add Buffer Space

  • Small items: +1-2″ length/width
  • Medium items: +2-3″ length/width
  • Large items: +3-4″ length/width

Common Products → Recommended Size:

  • Jewelry, cosmetics, phone cases → 6×9″
  • Single t-shirt, small accessories → 10×13″
  • 1-2 t-shirts, dress → 12×15.5″
  • Hoodie, jeans, multiple items → 14×19″
  • Jacket, large items → 19×24″

Testing: Order sample with actual product before 500+ units to ensure perfect fit.

Need Help? Send us product dimensions and photos – we’ll recommend optimal size.

Ready to Reduce Shipping Costs with Custom Shipping Bags?

Join thousands of e-commerce brands using custom shipping bags to save 30-50% on shipping costs while building brand recognition. Our packaging specialists are ready to help you choose the perfect size, materials, and design for your products. Start with just 500 bags.