Custom Poly Mailers in USA
A poly mailer does the work of two separate packaging layers in one. It is the shipping container and the brand presentation at the same time. Whatever is printed on the outside is the first thing the customer sees when the package arrives at the door. For ecommerce brands shipping clothing, accessories, and soft goods, that means the mailer is the unboxing experience. Custom poly mailers that carry clear brand colors, a logo, and a strong design communicate the brand as well as a retail box, at a fraction of the weight and material cost. EcoFold supplies custom printed poly mailers in standard and custom sizes with full-color flexographic printing, starting at 100 units with clear pricing before production starts.What Products Are Best Suited for Poly Mailers?
Not every product ships well in a poly mailer, and choosing the wrong format leads to damaged goods and customer service costs. Poly mailers are designed for products that are flexible, non-fragile, and not at risk from being compressed or folded during transit. Products that fit well: clothing, fashion accessories, scarves, hats, belts, small bags, promotional merchandise, soft goods, and subscription apparel. Products that need structural protection, are rigid, or are fragile generally need a box. For rigid or breakable items, Corrugated Boxes provide the structural support that a flexible mailer cannot. The weight and size of the product also matter: poly mailers work best for lighter shipments where the weight savings reduce per-shipment carrier costs in a meaningful way.Custom Poly Mailer Sizes and What They Hold
Poly mailers are sized by their usable interior dimensions, listed as width by length in inches. The table below maps common sizes to their typical product applications.| Size Label | Interior Dimensions | Common Products |
| Small | 6 x 9 in | Small accessories, jewelry, sunglasses, socks, keychains |
| Medium | 9 x 12 in | T-shirts, small folded garments, lightweight accessories |
| Standard | 10 x 13 in | Standard apparel, single folded clothing items |
| Large | 12 x 15.5 in | Multiple items, larger garments, activewear |
| Extra Large | 14.5 x 19 in | Heavy garments, multi-item orders, larger accessories |
Print Options for Branded Poly Mailers
Branded poly mailers use flexographic printing, which applies ink through flexible relief plates in a continuous process well suited to the large surface area of a mailer bag. The process handles solid colors, large typography, and brand patterns cleanly and cost-effectively across volume runs. Most custom poly mailer bags are printed in 1 to 4 solid colors. White and light-colored mailers on a white base are the most common format. Dark backgrounds, black, navy, deep forest green, are growing in popularity for brands that want a stronger shelf presence on the doorstep. Interior liner printing, where the inside surface of the mailer carries a pattern, brand color, or message, extends the branded moment from the exterior delivery into the opening experience. The exterior of the mailer is the first brand impression the customer receives. Choosing colors that communicate the right brand identity across different lighting conditions and delivery environments matters. Our guide on Packaging Colors That Sell covers how color selection communicates brand identity across different packaging surfaces and materials.Material and Thickness Options for Custom Poly Mailer Bags
Standard poly mailer bags are made from LDPE (low-density polyethylene), a flexible plastic that is tear-resistant, waterproof, and seals cleanly at the self-adhesive strip. Thickness is measured in mils (one mil equals 0.001 inch). 2.0 mil thickness is appropriate for most lightweight clothing and accessory shipments where the product is not heavy and the shipping route is standard carrier transit. 2.5 to 3.0 mil thickness for brands shipping heavier items or that want extra puncture and tear resistance through the carrier network. The added thickness also gives the mailer a more substantial feel when the customer handles it. Recycled-content poly mailers are made with post-consumer recycled LDPE, reducing the virgin plastic content of the shipping program. Standard poly mailers are not accepted in most US curbside recycling programs, though some national retailers operate drop-off recycling programs for plastic bags and flexible plastic film. Brands looking at biodegradable alternatives or paper-based shipping options alongside their poly mailer program can explore our Custom Eco-Friendly Boxes range for the recyclable and paper-based packaging options available for ecommerce and retail shipping.Design Considerations for Custom Printed Poly Mailers
Designing for a poly mailer requires different decisions than designing for a rigid carton. A few practical points before the artwork file goes to production. The mailer surface is flexible and may have slight texture variation. Very fine typography and intricate small details may not reproduce with the same crispness as they would on a flat SBS carton. Bold logos, large block type, and clean graphic patterns reproduce well consistently across flexographic print on LDPE. The adhesive seal strip runs across the top of the mailer and needs clear space. Any design element that extends into the seal zone will be partially obscured when the mailer is closed and sealed. Artwork should be built with the seal area identified in the template before layout begins. Some brands add a QR code to the exterior of the mailer linking to a returns page, a loyalty program, or a welcome video. The flat surface of a closed mailer is easy to scan with a smartphone, making it a practical location for a secondary brand interaction after delivery. Before deciding between a flat poly mailer and a self-locking mailer box format, our guide on Mailer Boxes vs Shipping Boxes covers the differences in structure, protection, and branded unboxing between the two formats.Who Orders Custom Poly Mailers?
Fashion and apparel brands shipping direct-to-consumer clothing, footwear, and accessories are the primary buyers. The poly mailer is the standard lightweight shipping format for soft goods at every price tier from mass market to premium boutique. Subscription brands building a monthly membership program around clothing, beauty products, or merchandise use custom shipping mailers to create a consistent branded delivery experience across every shipment cycle.- Ecommerce brands in accessories, activewear, and sportswear that need lightweight shipping packaging to manage per-shipment carrier costs as order volumes increase
- Promotional merchandise companies shipping branded items in bulk for events, corporate gifting, and brand activation programs
- Boutique and independent fashion brands for whom the mailer exterior is the primary brand packaging surface for every customer order
- Beauty and personal care brands shipping non-fragile products such as makeup brushes, accessories, and soft goods where a box would add unnecessary weight
- ECommerce poly mailers ordered by multichannel retailers building a consistent delivery presentation across online orders that arrive separately from in-store products
Why Brands Order From EcoFold
- MOQ starts at 100 units with wholesale poly mailers pricing tiered by quantity
- Standard sizes from 6x9 to 14.5x19 inches and custom dimensions available
- LDPE in 2.0, 2.5, and 3.0 mil thickness options
- Recycled-content LDPE available for brands with sustainability requirements
- Flexographic printing in 1 to 4 solid colors with full front panel coverage
- Interior liner printing available for brands that want to extend the branded moment inside the mailer
- Self-adhesive peel-and-seal closure standard on all mailers
- Clear pricing before production starts
- Ships to businesses across the USA