Poly Bags & MailersCustom Packaging
Custom Poly Mailers & Shipping Bags — Lightweight, Branded E-Commerce Packaging
Key Takeaways — Custom Poly Bags & Mailers
MOQ
500 units
Lead Time
10-15 days
Printing
Full Color CMYK
Eco Options
FSC Certified
Shipping
Free Shipping
What Are Custom Poly Bags & Mailers?
Poly mailers are lightweight, flexible shipping envelopes made from co-extruded polyethylene (LDPE/HDPE) film — the most cost-effective way to ship soft goods, apparel, accessories, and lightweight products. Over 2.5 billion poly mailers are shipped annually in the US alone, making them the dominant e-commerce packaging format for non-fragile items.
Custom poly mailers cost **$0.08–$0.80 per unit** depending on size, film thickness, printing, and features. Basic white poly mailers start at $0.08/unit, while premium full-color printed mailers with dual-peel return strips and recycled content run $0.30–$0.80/unit.
Poly mailers are manufactured from **co-extruded film** — an opaque outer layer (white, grey, or custom color) bonded to a dark inner layer (typically black or grey) that blocks contents from view. Standard thickness ranges from **2.5 mil** (lightweight, budget) to **4 mil** (heavy-duty, premium feel). All poly mailers include a **self-seal adhesive strip** for tamper-evident closure.
Available formats include: **flat poly mailers** for clothing and documents; **bubble poly mailers** with integrated bubble wrap lining for moderate protection; **expansion poly mailers** with side gussets for thicker items; **clear poly bags** for product packaging and FBA prep; and **compostable mailers** made from PBAT/PLA blends for eco-conscious brands (ASTM D6400 certified).
Key features: self-seal adhesive closure, dual-peel return strips (second adhesive strip for easy returns), tear-resistant co-extruded film, waterproof construction, lightweight (reduces DIM weight shipping costs by 30–50% vs boxes). MOQ starts at 500 mailers with 7–10 day production.
Specifications
Detailed technical information for informed decisions.
Film Specifications
- MaterialLDPE co-extruded, white/grey/custom
- Thickness2.5, 3.0, 4.0 mil standard
- AdhesivePermanent self-seal, 2nd peel strip optional
- Opacity100% interior grey co-extrusion
Sizes
- Small6x9, 7.5x10.5, 9x12 inches
- Medium10x13, 12x15.5 inches
- Large14.5x19, 19x24 inches
- CustomAny dimension to 24x36 inches max
Printing
- MethodFlexographic, up to 4 colors
- CoverageFull-bleed front, back, and flap
- Plate Cost$100-200 per color, stored free
- Color MatchPantone PMS standard matching
Printed poly mailers that weigh almost nothing. Ideal for clothing, soft goods, and non-fragile items.
Custom Poly Mailers
Ship your orders in poly mailers that decompose, not just get recycled. ASTM D6400 compliant.
Biodegradable Poly Mailers
Bubble-lined poly mailers that protect fragile items without the weight of a box.
Bubble Poly Mailers
See-through poly bags for apparel, accessories, and retail bundling. Multiple thickness options.
Clear Poly Bags
Poly or non-woven garment bags for shipping and retail display. Clear, frosted, or fully branded.
Garment Bags
Cotton or velvet drawstring bags for shoes, jewelry, and accessories. Adds a luxury layer to any package.
Drawstring Bags
Printed envelopes for documents, invitations, and flat shipments. Peel-and-seal closure.
Custom Mailer Envelopes
Bubble-lined envelopes for phones, jewelry, and small electronics. Lightweight, peel-and-seal.
Padded Envelopes
Available Pouch Formats
Choose from a variety of pouch structures designed for different products and shelf presentations.
Standard Poly Mailer
Co-extruded LDPE film mailer with permanent self-seal adhesive. White exterior, opaque grey interior. Available in 10 standard sizes from 6x9 to 19x24 inches. 2.5 mil standard thickness.
Bubble Poly Mailer
Poly mailer with integrated bubble cushion lining for fragile items. Self-seal closure. Available in metallic, white, and kraft exterior finishes. Bubble layer adds 3mm of impact protection.
Dual-Peel Return Mailer
Two adhesive strips — first for initial sealing, second for customer returns. Perforated tear strip for clean opening. Required by many fashion and apparel e-commerce brands.
Eco Recycled Mailer
Made from 100% post-consumer recycled LDPE plastic. Slightly textured grey surface. Same tear resistance and waterproofing as virgin poly. GRS (Global Recycled Standard) certified.
Compostable Mailer
Plant-based PBAT/PLA film that breaks down in commercial composting within 90 days. ASTM D6400 certified. Matte finish with limited color printing. The zero-plastic shipping option.
Clear Poly Bag
Transparent LDPE bag for product packaging, bundling, and retail display. Available with lip-and-tape self-seal, resealable zipper, or open top. Thicknesses from 1 to 4 mil.
Built With Quality
Detailed view of the materials we use.
Co-Extruded LDPE Film
Three-layer co-extruded low-density polyethylene with white exterior, grey opaque interior, and clear adhesive liner. Provides waterproofing, tear resistance, and content concealment. Standard 2.5 mil for lightweight items, 3-4 mil for heavier products.
100% Recycled LDPE
Post-consumer recycled polyethylene in grey or white. GRS (Global Recycled Standard) certified. Same performance as virgin LDPE — waterproof, tear-resistant, and fully functional with self-seal adhesive. Recyclable again after use.
Compostable PBAT/PLA Film
Plant-based bioplastic blend of polybutylene adipate terephthalate and polylactic acid. Breaks down in commercial composting facilities within 90 days. ASTM D6400 and EN 13432 certified. Matte finish with slightly softer hand-feel than LDPE.
Bubble Cushion Lining
Air-filled LDPE bubble layer laminated to the mailer interior. Standard 3/16-inch bubble diameter provides shock absorption for fragile items. Adds approximately 3mm of total cushioning.
Self-Seal Adhesive
Permanent pressure-sensitive adhesive strip covered by a release liner. Peel and press to seal — no water, heat, or tape needed. Bond strength exceeds 1.5 lbs/inch peel force. Second adhesive strip available for return mailers.
Printing & Finishing
Premium print methods and finishing options to make your packaging stand out.
1-Color Flexo Print
Single-color logo repeat across the mailer surface. The most cost-effective branded option. Clean, professional look on white or colored poly film.
2-Color Flexo Print
Brand logo plus secondary element (tagline, URL, social handle) in two colors. Adds brand depth at minimal additional cost. The most popular configuration for e-commerce brands.
4-Color Process
Full CMYK printing for photographic-quality artwork, gradients, and complex designs. Covers the entire exterior surface. Premium option for brands where the mailer IS the packaging.
Custom Colored Film
Manufacture the poly film in any custom color — matte black, blush pink, forest green, any Pantone shade. Print your design over the custom base color for a fully branded mailer.
Metallic Finish
Holographic, chrome silver, or rose gold metallic poly film with custom printing. Eye-catching metallic shimmer that stands out in a pile of brown cardboard deliveries.
Inside Printing
Print on the interior white layer of the mailer. Customers see a branded message or pattern when they open the package. Creates a second brand touch at zero additional material cost.
QR & Variable Data
Digital printing overlay for unique QR codes, sequential numbers, or personalized messages on each mailer. Track shipments, drive app downloads, or surprise customers with custom notes.
Eco-Friendly Inks
Water-based and soy-based inks for recycled and compostable mailers. Maintain print vibrancy without compromising recyclability or compostability certifications.
Unlimited Customization
Every inch of your packaging can be customized to match your brand.
Custom Film Color
Manufacture poly film in any Pantone color — matte, satin, or gloss finish. Popular choices: matte black, blush pink, sage green, navy blue. Custom color requires 5,000 unit minimum.
Dual-Peel Return Strip
Second adhesive strip below a perforated tear line. Customers open the mailer by tearing the perforation, then reseal for returns using the second strip. Reduces returns processing cost.
Suffocation Warning Print
Required FTC suffocation warning text pre-printed on all poly bags shipped to consumers. We print the warning in the required minimum 18pt type as standard on every custom order.
Expansion Gusset
Side and bottom gussets add volume capacity for bulky items like sweaters and shoes. Standard flat mailers expand to 2-4 inches of depth when gusseted. Custom gusset widths available.
Document Pocket
Adhesive-backed clear envelope on the exterior for packing slips and shipping labels. Eliminates tape and separate label pouches. Available on the flap-side for clean front-panel branding.
Tear Strip Opening
Perforated tear strip positioned 1 inch below the top seal for clean, easy opening. Customers pull the strip for a straight, clean edge — no scissors or knife needed.
From Idea to Impact
Get your custom packaging in 4 easy steps.
Choose Mailer Type & Size
Pick from standard, bubble, dual-peel, recycled, compostable, or clear formats. Select size based on your product dimensions plus 1-2 inches of clearance. We ship size samples if you need to test fit.
Design Your Mailer
Send your logo and brand colors. We create the flexo plate artwork with proper repeat pattern, bleed, and registration. You approve a digital mockup showing the flat and sealed mailer.
Plate Setup & Production
Flexographic plates are cut and production runs 7-10 business days. Each mailer is inspected for print registration, adhesive performance, and film integrity. Plates stored free for reorders.
Ship & Fulfill
Mailers arrive flat-packed in master cartons — typically 500-1,000 per carton. Ready for your fulfillment line immediately. Free shipping on 5+ carton orders. Reorders ship in 3-5 days.
Key Features & Benefits
Everything you need for premium custom packaging.
Weighs Under 1 oz
A 10x13 poly mailer weighs 0.7 oz versus 8+ oz for an equivalent box. Dimensional weight savings reduce USPS and UPS shipping costs by $0.50-1.50 per package.
Full-Surface Printing
Print your brand across the entire exterior — front, back, and closure flap. Up to 4-color flexo on white, grey, or custom-colored poly. Full-bleed coverage with no blank margins.
Waterproof & Tear-Resistant
Co-extruded LDPE film resists water, punctures, and tearing. Internal grey layer blocks visibility of contents. Products arrive dry and secure even in rain and snow.
Dual-Peel Returns Strip
Second adhesive strip below the primary seal enables customers to reseal and return products without additional packaging. Reduces return logistics cost and improves customer satisfaction.
Trusted by brands in
Frequently Asked Questions
Why Order Poly Bags & Mailers from Cubit?
A complete packaging platform — not just a printer. Design, order, track, and protect.
Not sure what you need?
Our AI Packaging Consultant can analyze your product and recommend the perfect specs in seconds.
Poly Bags & Mailers
Custom Poly Mailers
Printed poly mailers that weigh almost nothing. Ideal for clothing, soft goods, and non-fragile items.
Poly Bags & Mailers
Biodegradable Poly Mailers
Ship your orders in poly mailers that decompose, not just get recycled. ASTM D6400 compliant.
Poly Bags & Mailers
Bubble Poly Mailers
Bubble-lined poly mailers that protect fragile items without the weight of a box.
Poly Bags & Mailers
Clear Poly Bags
See-through poly bags for apparel, accessories, and retail bundling. Multiple thickness options.
Poly Bags & Mailers
Garment Bags
Poly or non-woven garment bags for shipping and retail display. Clear, frosted, or fully branded.
Poly Bags & Mailers
Drawstring Bags
Cotton or velvet drawstring bags for shoes, jewelry, and accessories. Adds a luxury layer to any package.
Poly Bags & Mailers
Custom Mailer Envelopes
Printed envelopes for documents, invitations, and flat shipments. Peel-and-seal closure.
Poly Bags & Mailers
Padded Envelopes
Bubble-lined envelopes for phones, jewelry, and small electronics. Lightweight, peel-and-seal.
Design your Poly Bags & Mailers packaging free in 60s
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