E-commerce & DTC
Branded unboxing that gets shared
Explore E-commerceShipping & Fulfillment
Custom Poly Mailers
Custom poly mailers and bubble mailers for apparel and soft goods. Lightweight, tear-resistant, and printable, with recycled and compostable options.
Technical Specifications for Custom Poly Mailers
- Material
- Coextruded poly, recycled poly, compostable film
- Thickness
- 2.5 mil to 4 mil
- Closure
- Permanent self-seal + tear strip
- Turnaround
- 8–12 business days standard
Materials
- Coextruded polyethylene
- Recycled poly
- Compostable mailer film
- Bubble lining
Print & Finishing
- Flexographic print
- Full-color
- Single-color logo
- Compostable-safe inks
Available Styles
- Standard Poly Mailers
- Bubble-Lined Mailers
- Recycled Poly Mailers
- Compostable Mailers
Custom Poly Mailers for Apparel & Soft-Goods Shipping
Custom poly mailers are lightweight, tear-resistant polyethylene envelopes engineered for outbound shipping of soft goods — apparel, textiles, accessories, and non-fragile DTC orders where dimensional weight and pack speed matter more than rigid structure. Full-color print turns the shipper into brand media; peel-and-seal closures keep pack stations fast.
BoxYourBrand produces custom poly mailers and bubble mailers in coextruded poly, recycled poly, and compostable film from 2.5 mil through 4 mil thickness — with permanent self-seal, tear strips, and optional dual-seal returns strips.
What fulfillment teams get from custom poly mailers:
- Lower ship cost — Minimal cube vs boxes; often wins on DIM for apparel
- Pack speed — Peel-and-seal faster than tape-and-fold corrugated
- Moisture resistance — Film sheds rain better than paper mailers
- Brand print — Full-color and spot logo on opaque or clear film
- Returns-friendly options — Dual-seal strips for easy customer returns
Rigid or fragile SKUs belong in mailer boxes or corrugated shipping boxes. Retail pouches and product bags — not outbound shippers — live under plastic packaging. See e-commerce packaging for channel guidance.
Types of Mailers: Poly, Corrugated & Bubble Compared
“Types of mailers” spans three families — poly film, corrugated mailers, and bubble-lined formats — each optimized for different weight, fragility, and brand goals. Most apparel brands standardize on one poly SKU and one box SKU for exceptions.
| Mailer type | Structure | Best for | Brand / cost profile |
|---|---|---|---|
| Standard poly mailer | Coextruded PE film | Apparel, soft goods, textiles | Lowest cube; full-color film print |
| Bubble mailer | Poly + bubble lining | Accessories, small electronics, books | Light padding; moderate cube |
| Recycled poly mailer | Post-consumer resin film | Eco-positioned apparel brands | Similar to standard poly; document resin % |
| Compostable mailer | Certified compostable film | Sustainability-led DTC | Premium film cost; verify end-of-life claims |
| Corrugated mailer box | E-flute self-lock carton | Premium unboxing, moderate weight | Higher cube; interior print available |
| Mylar / high-barrier bag | Metallized film | Collectibles, food-adjacent storage | Not a shipper replacement for apparel |
Read the full types of mailers: corrugated, poly & mylar compared for decision trees by SKU weight and channel. Corrugated mailer detail lives on the mailer boxes product page.
Apparel-specific kitting — tissue, stickers, dual-format outbound — is covered in the custom apparel packaging guide.
Customizable mylar bags and comic storage formats appear in the same “types of mailers” search cluster as poly mailers — they are high-barrier product bags for collectibles, not substitutes for outbound apparel mailers unless the SKU is flat, light, and non-fragile. Freeze-dried food and supplement brands evaluating mylar should compare barrier needs against stand-up pouches under plastic packaging.
Poly Mailer Styles & Common Sizes
Poly mailer sizing follows folded garment thickness, not just length × width — a hoodie needs a different gusset assumption than a tee in a bag. Standard catalog sizes exist, but custom dimensions reduce wasted film and awkward folds.
| Common size (W × L) | Fits | Typical mil |
|---|---|---|
| 6 × 9" | Jewelry, socks, small accessories | 2.5 mil |
| 7.5 × 10.5" | Single tee, small flat items | 2.5–3 mil |
| 10 × 13" | Folded apparel, soft goods | 3 mil |
| 12 × 15.5" | Hoodies, multiple items | 3–4 mil |
| 14.5 × 19" | Large apparel, bulk textiles | 4 mil |
| Custom | Brand-specific fold geometry | Spec'd to puncture needs |
Thickness from 2.5 mil to 4 mil trades puncture resistance against cost and hand-feel. Heavier denim and multi-item orders should move up in mil or switch to bubble mailers for edge protection.
Custom width and length matter when folding differs by garment type — a mailer sized for a flat tee wastes film on a bundled hoodie. Share your fold schematic or sample pick photos when quoting custom dimensions so gusset assumptions match reality.
Bag and mailer format comparisons for retail vs ship are in the custom packaging bags guide.
Film Materials, Thickness & Closures
Film material drives sustainability claims, opacity, and how the mailer behaves in pack-out and returns. Coextruded PE is the default; recycled and compostable films suit brands with documented end-of-life requirements.
Material and closure options:
- Coextruded polyethylene — Standard tear-resistant shipper film
- Recycled poly — Post-consumer resin content where clarity and strength allow
- Compostable mailer film — Certified options for sustainability-led programs
- Bubble lining — Lightweight padding for semi-fragile SKUs
- Permanent self-seal — Standard peel-and-seal adhesive strip
- Dual-seal returns strip — Second adhesive path for customer returns
- Tear strip — Easy open without scissors; improves unboxing
Opaque films protect privacy for apparel; clear windows are rare on outbound poly mailers but common on retail bags under plastic packaging. Compostable and recycled films may need different ink systems — share sustainability claims you plan to print when quoting.
Print, Opacity & Brand Placement on Poly Mailers
Custom printed poly mailers use flexographic or full-color film print — logo placement should account for fold lines, adhesive zones, and carrier label areas. Dark garments in opaque mailers need sufficient ink opacity so brand color reads on the dock and in customer photos.
Print options:
- Full-color process — Edge-to-edge brand patterns on opaque film
- Single-color logo — Economical at high volume
- Spot color — Exact brand match on repeat orders
- Compostable-safe inks — Required on certified compostable film
- Interior tint — Opaque white or grey lining for privacy
Reserve clean panels for shipping labels — ink-heavy zones under labels reduce scan reliability. Request samples to approve opacity and color on film before a bulk run; film print looks different than paperboard proofs.
Compare poly print economics to corrugated in the types of mailers guide when your team debates box vs mailer for a new SKU.
Poly Mailers vs Mailer Boxes vs Corrugated Shippers
Pick poly when the SKU is soft and non-fragile; pick corrugated when structure, weight, or unboxing elevation demands it. Many catalogs run poly for single-item apparel and mailers for gift-tier or influencer orders.
| Factor | Poly mailer | Mailer box | Corrugated shipper |
|---|---|---|---|
| Typical weight | Soft goods, < ~2 lbs | ~0.5–5 lbs | 5–20+ lbs |
| Protection | Tear & moisture; minimal crush | Moderate E-flute structure | Highest stacking strength |
| Unboxing | Minimal; tear strip helps | Premium; interior print | Functional to branded |
| DIM / cube | Lowest | Moderate | Highest when oversized |
| MOQ profile | 100–499 launch typical | 50–249 launch typical | 50–249 launch typical |
| Best for | Apparel, textiles, cost-sensitive DTC | Beauty, subscription, PR kits | Heavy, fragile, multi-item |
The mailer box vs shipping box guide covers corrugated mailer detail. Mylar and high-barrier bags — common for collectibles and comics — are product bags, not poly mailer replacements; see the types-of-mailers guide for when mylar fits.
10 × 13 poly mailers remain the most quoted apparel size because they cover a folded tee or single-layer hoodie with minimal film — but denim stacks and two-item orders often need 12 × 15.5 or custom length. Run your fold against sample sizes before locking a one-size-fits-all SKU matrix.
Fulfillment Speed, Returns & 3PL Integration
Poly mailers exist to keep pack stations fast — peel, fold, seal, label. Dual-seal returns strips add a second adhesive path so customers reseal without tape, which measurably improves apparel return completion rates when the policy is print on the mailer itself.
3PL integrations should document one poly SKU per product line with clear mil and size rules in the WMS — mixed mailer sizes at the same pick station create the most common mis-ship errors in soft-goods fulfillment. Opaque white or grey interior films prevent show-through on dark garments in branded full-color mailers.
Subscription apparel and accessory brands on subscription box programs sometimes use poly for replenishment SKUs and corrugated mailers for curated monthly kits — share your pick logic when quoting both formats.
Recycled & Compostable Poly Mailer Options
Sustainable poly mailers require matching film, ink, and on-pack claims to what your customers can actually compost or recycle. Recycled PE and compostable film are both available; neither is universal curbside recyclable in the US.
Recycled-content poly mailers document post-consumer resin percentage for retailer scorecards. Compostable mailers need certified film and compatible inks — verify municipal and home compost acceptance before printing broad “compostable” claims. Explore eco-friendly packaging and the sustainability hub for cross-format guidance.
Brands comparing compostable mailers to recycled corrugated should read compostable vs corrugated comparisons on the eco-friendly packaging line — many apparel brands run recycled poly for outbound and kraft mailers for premium tiers.
MOQ, Pricing & Ordering Poly Mailers
Poly mailer MOQs reflect plate setup on film print — launch tiers remain accessible for Shopify and Etsy-scale brands.
Typical program structure:
- MOQ — 100–499 units launch tier
- Volume tiers — Breaks at 500–2,499 and 2,500+ units
- Production — 8–12 day standard turnaround; 3–5 day rush available
- Reorders — Approved artwork and plate spec stay on file
- Multi-size programs — One print design across sizes reduces art costs
When you request a poly mailer quote, send target size, mil thickness, film type (standard, recycled, compostable), print coverage, and monthly ship volume. Include whether you need dual-seal returns strips for your returns policy.
Order samples ($25, credited toward your first order) to validate seal strength, opacity, and tear-strip function before production.
Bubble mailers add cost per unit but reduce damage claims on semi-fragile SKUs that are too light for a box — compare claim rate vs mailer cost when debating bubble vs standard poly for accessories and small hard goods.
Start Your Custom Poly Mailer Order
Ready to replace plain poly bags with branded mailers sized to your apparel line? Request a free quote with dimensions, film type, and quantity. A specialist responds within two hours with per-unit pricing at your tier.
Start with the types of mailers guide and apparel packaging guide if you are still choosing between poly, bubble, and corrugated formats.
Common Uses for Custom Poly Mailers
Businesses order custom poly mailers for the applications below.
Apparel and fashion shipping
Soft goods and textiles
Lightweight e-commerce orders
Returns-friendly dual-seal mailers
Poly & Bubble Mailers Pricing & Order Quantities
100-499 units
Launch tier
500-2,499 units
Volume discount tier
2,500+ units
Best per-unit pricing
Exact pricing depends on dimensions, material, print, and quantity. Request a free quote for a precise per-unit price.
Industries That Order Poly & Bubble Mailers
custom poly mailers pairs well with custom printed poly mailers across these verticals.
Subscription Boxes
Consistent supply, custom inserts, seasonal flexibility
Explore Subscription BoxesRetail & CPG
Shelf-ready formats built for planogram compliance
Explore Retail & CPGGuides for Designing Poly & Bubble Mailers
Expert guides on custom poly mailers — sizing, design, materials, and ordering.
Buying Guide
Types of Mailers: Corrugated, Poly & Bubble
Types of mailers explained — corrugated mailer boxes, poly mailers, bubble mailers, mylar bags, and subscription box formats. Sizes, MOQs, and when each wins.
Buying Guide
Custom Packaging Bags Guide
Custom packaging bags compared — paper, kraft, and poly mailers for retail, ecommerce, and food brands. MOQs, print methods, and format fit.
Buying Guide
Custom Apparel Packaging Guide
Custom packaging for clothing and custom apparel packaging — mailer boxes, poly mailers, tissue, and shipper combos for DTC and wholesale apparel brands.
FAQ
Poly & Bubble Mailers Questions
When should I use a poly mailer instead of a box?
Poly mailers are ideal for non-fragile soft goods like apparel and textiles. They reduce dimensional weight and shipping cost while still offering a brandable surface, whereas boxes are better for rigid or fragile products.
Do you offer recycled or compostable poly mailers?
Yes. We offer mailers made from recycled polyethylene as well as certified compostable mailer film for brands prioritizing sustainability.
Can poly mailers include a returns seal?
Yes. Dual-seal mailers include a second adhesive strip so customers can reseal and return items easily, improving the post-purchase experience.
Are poly mailers waterproof for apparel and soft goods?
Yes. Poly mailers shed rain and moisture better than paper mailers for apparel, soft goods, and returns-heavy programs. We can add resealable strips and opaque films for privacy.
Can poly mailers be printed full-bleed with our brand?
Yes. Full-color and spot-branded poly mailers turn the shipper into mobile advertising. Request samples if you need to approve opacity and color on film before a bulk order.
What are the types of mailers for ecommerce shipping?
Common mailer types include standard poly mailers, bubble mailers, corrugated mailer boxes, and compostable or recycled film mailers. Poly suits soft apparel; corrugated mailers suit premium unboxing; bubble mailers add light padding. See our types of mailers guide.
When should I use a poly mailer instead of a box?
Poly mailers are ideal for non-fragile soft goods like apparel and textiles. They reduce dimensional weight and shipping cost while offering a brandable surface. Boxes are better for rigid, fragile, or multi-item orders that need crush protection.
What is the MOQ for custom poly mailers?
Launch programs often start at 100–499 units. Per-unit pricing improves at 500–2,499 units and again at 2,500+ units. Your quote itemizes pricing at the quantity you request.
Do you offer recycled or compostable poly mailers?
Yes. We offer mailers made from recycled polyethylene as well as certified compostable mailer film for brands prioritizing sustainability. Share your end-of-life claims requirements when quoting.
Can poly mailers include a returns seal?
Yes. Dual-seal mailers include a second adhesive strip so customers can reseal and return items easily, improving the post-purchase experience.
Are poly mailers waterproof for apparel shipping?
Yes. Poly mailers shed rain and moisture better than paper mailers for apparel and soft goods. Opaque films also protect privacy for garment contents.
How do poly mailers compare to custom plastic packaging bags?
Poly mailers are optimized for outbound shipping. Custom plastic packaging covers retail pouches, product bags, and rigid formats for shelf presentation. Many brands use both — pouches for product, poly mailers for fulfillment.
How long does poly mailer production take?
Standard production takes 8–12 business days after proof approval after digital proof approval. Rush production of 3–5 business days is available when quoted.
Can I get samples before a full poly mailer order?
Yes. Physical samples are $25, credited toward your first full order, and ship within 5–10 business days. Digital proofs are always free before production.
Products Related to Poly & Bubble Mailers
Brands ordering custom poly mailers often compare these formats before requesting a quote.
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