Poly Mailer
Also known as: Polymailer, Plastic Mailer, Shipping Bag
Definition
A poly mailer is a plastic shipping bag made from polyethylene, used to ship soft goods and non-fragile items. They’re lightweight, water-resistant, and cheaper to ship than boxes due to their minimal weight and flexible dimensions.
Poly Mailer Advantages
Cost savings:
- Weighs ounces vs. box weight
- No void fill needed
- Lower dimensional weight
- Cheaper material than boxes
Convenience:
- Self-sealing adhesive strip
- No tape required
- Easy storage (flat)
- Quick packing
Protection:
- Water-resistant
- Tear-resistant
- Tamper-evident seal
- Opaque (contents hidden)
Common Poly Mailer Sizes
| Size | Best For |
|---|---|
| 6" × 9" | Small items, jewelry, accessories |
| 10" × 13" | T-shirts, small apparel |
| 12" × 15.5" | Sweatshirts, larger apparel |
| 14.5" × 19" | Multiple items, bulky clothing |
| 19" × 24" | Jackets, large items |
When to Use Poly Mailers
Ideal for:
- Clothing and apparel
- Soft goods (linens, fabrics)
- Books and documents
- Non-fragile accessories
- Bags and soft cases
Avoid for:
- Fragile items
- Electronics
- Rigid products
- Items needing padding
- Heavy items (tears easily)
Poly Mailer Cost Comparison
| Package Type | Material Cost | Shipping (1 lb, Zone 5) |
|---|---|---|
| Poly mailer | $0.15-0.30 | $5-7 (Priority) |
| Small box + fill | $0.75-1.50 | $8-12 (DIM weight) |
| Savings | $0.50-1.20 | $2-5 |
The shipping difference is often larger than material savings.
Types of Poly Mailers
Standard Poly
- Most common
- Basic protection
- Economical
Bubble Poly Mailers
- Padded interior
- More protection
- For semi-fragile items
- Higher cost
Co-Extruded Poly
- Two-layer construction
- Better tear resistance
- Premium option
Recycled/Eco Poly
- Made from recycled content
- More sustainable option
- Growing in popularity
Poly Mailer Tips
- Size appropriately - Snug fit looks professional
- Don’t overstuff - Seams can split
- Consider branding - Custom printed options available
- Use bubble for padding - When item needs protection
- Check carrier rules - Some services require boxes
Environmental Considerations
Challenges:
- Not curbside recyclable in most areas
- Plastic pollution concerns
- Customer perception issues
Alternatives:
- Recycled content poly mailers
- Compostable mailers (though pricier)
- Paper mailers for appropriate items
- Recycling program participation
Labeling Poly Mailers
- Labels adhere well to smooth surface
- Place on center, avoiding seams
- Avoid placing over folds
- Thermal labels work best
- Ensure barcode is flat and scannable
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