Custom Poly Mailers

Boxbaba manufactures custom poly mailers engineered for ecommerce, retail, wholesale and PR distribution. Produced in LDPE or co-extruded recycled films, they are available in 2–6 mil thickness with CMYK and PMS printing, matte or gloss finishes and optional dual-seal closures. Fully customizable sizing reduces dimensional weight while maintaining moisture and tear resistance. MOQs start at 100 units with structured lead times and free USA shipping, supporting scalable operations from startups to enterprise fulfillment networks nationwide.

4.3 Reviews 8 • Excellent

Andrew Diedrich

Greatest P......

My contact at BoxBaba, Marcel, was very tentative and responsive. He gave me all box outlines…

Date of experience:

Dec 2, 2025

Matt Lab

Greatest P......

These guys are legit Top-notch service and high quality products.

Date of experience:

Sep 19, 2024

Myralyn

Greatest P......

We recently purchased box sleeves and we couldn’t be happier with both the product and the service we received…

Date of experience:

Feb 15, 2025

Hannah Ahmed

Greatest P......

For our recent product launch, we needed packaging that would really make an impression. The custom boxes from BoxBaba…

Date of experience:

Apr 26, 2025

Matteo

Greatest P......

I’ve been very pleased with my experience with BoxBaba and Cristina from Customer Service to communicate our…

Date of experience:

Apr 29, 2025

Carol Scott

Greatest P......

Absolutely phenomenal service and product! David Wells far exceeded expectations to deliver high-quality custom…

Date of experience:

Jul 9, 2025

Doug C

Greatest P......

Marcel and David are very responsive, thorough and a pleasure to work with. I appreciated their efforts to customize…

Date of experience:

Jul 15, 2025

Jess B

Greatest P......

I’ve loved working with BoxBaba. Their representatives have been extremely responsive and their prices are very…

Date of experience:

Sep 10, 2025

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Upload Your Design

Design

Get your custom boxes made in the required size, shape, and style.

Print

Upload your artwork and get it superbly printed the way you want.

Get it done

Order any quantity, enjoy a wholesale price, pay no extra for die plates.

Product Specification

Product Specifications

Feature	Specification
Material Options	LDPE, Co-extruded PE, Recycled PE
Thickness Range	2–6 mil (50–150 microns approx.)
Closure	Self-seal adhesive, Dual return strip
Printing	Flexographic, Multi-color, Inside/Outside
Finish	Matte, Gloss
Custom Sizing	Fully customizable
Security Options	Opaque interior, Tamper-evident seal
MOQ	Flexible depending on size & print complexity
Sample Availability	Free samples (delivery reimbursed on first bulk order)
Shipping	Free across USA

Shipping

We have Air, Ground, and Sea shipping options available depending on the manufacturing origin and destination. Our Trusted partners are DHL. FEDEX & UPS.

Material

We comprehend that finding the ideal custom packaging Material to meet your requirements can be quite challenging. To make it easier for you, we've assembled a collection of material options, carefully chosen based on their capabilities like SBS Cardstock (16 to 24 pt), Eco-Friendly Kraft, Corrugated (E, B, AB etc. flutes)

Ads-Ons & Finishing

Explore our finest collection of premium finishes to give a magnificent look and feel to your custom packaging while increasing its protectiveness. You can Choose Foiling, Holographic Foiling, Aqueous Coating, Embossing/Debossing, Gloss/Matte Lamination, Soft Touch, Spot UV/Spot Gloss

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Precision Film Engineering for Cost-Efficient Shipping

Every Boxbaba poly mailer is specified by film grade, thickness and seal strength to match product weight and transit stress. Controlled print registration, custom sizing and return-ready closures ensure consistent packing performance across ecommerce and wholesale distribution channels.

Lightweight, Branded Shipping Packaging Built for Ecommerce Scale, Cost Control and Brand Impact

Custom Poly Mailers are flexible polyethylene shipping envelopes engineered for secure ecommerce fulfillment. They protect soft goods from moisture, tearing and transit wear while transforming every shipment into a branded touchpoint. Unlike stock courier bags, custom mailers are sized to reduce DIM weight, printed to reinforce brand identity and configured for operational efficiency. For growing brands, retailers and wholesale distributors, they influence freight cost, return handling and customer perception.

Why Businesses Choose Custom Poly Mailers

Freight Optimization Without Compromising Protection

Lower dimensional weight than corrugated cartons
Reduced shipping cost per unit
Space-efficient warehouse storage
Ideal for apparel, textiles, accessories and durable non-fragile goods

Branded Delivery Experience

Full-surface exterior printing
Matte or gloss finish options
Inside print messaging for post-purchase engagement
QR codes for promotions or return portals

Operational Efficiency

Peel-and-seal adhesive closures
Dual adhesive strip for returns
Flat-packed bulk shipping
Fast packing-line integration

Poly mailers are especially effective for ecommerce brands shipping items traditionally housed in Rigid Apparel Boxes or secondary cartons where rigid protection is unnecessary.

Types of Poly Mailers Available

Standard opaque poly mailers
Return-ready dual seal mailers
Bubble-lined protective mailers
Security tint interior mailers
Custom finish mailers (matte, gloss, soft-touch)

For heavier or higher-value items, mailers may complement rigid solutions such as Custom Rigid Mailers, Magnetic Closure Boxes or Luxury Rigid Boxes for premium product lines.

Materials & Film Options

Film Types

LDPE (Low-Density Polyethylene)
Co-extruded multilayer polyethylene
Recycled-content poly (PCR options available on request)

Thickness Options

2–3 mil (approx. 50–75 microns) for apparel and lightweight goods
4–6 mil (approx. 100–150 microns) for higher-value or heavier items

Thickness directly impacts puncture resistance, perceived quality and durability.

Popular Use Cases by Industry

Apparel brands replacing rigid cartons
Beauty brands shipping items like Custom Cosmetic Boxes, Lipstick Boxes or Lip Gloss Boxes as outer protection
Skincare and fragrance brands shipping Perfume Boxes and Fragrance Packaging
Food brands pairing outer poly mailers with inner formats like Food Mylar Bags, Coffee Bags, or Custom Beef Jerky Packaging Bags
Pet brands using outer mailers for Pet Treat Mylar Pouches

Size Selection Guidance

Selecting the correct size reduces void space and freight cost. Consider:

Folded product dimensions
Desired packing tolerance
Film thickness requirement
Label placement area

For businesses also selling flat flexible packaging such as Flat Mylar Bag, Side Gusset Pouch, Window Mylar Bags, Lay Flat Pouches or Flat-Bottom Box Pouches, poly mailers function as cost-efficient secondary protection during shipment.

Customization Options

Structural Customization

Fully custom dimensions
Bottom-seal or side-seal formats
Gusseted expansion options

Printing Options

Flexographic printing
Multi-color branding
Inside and outside print
Pantone matching (upon request)

Functional Add-Ons

Dual adhesive return strip
Tamper-evident seal
Security tint interior
Barcode or QR integration

Sustainability Options

Available options may include:

Mono-material recyclable film
Post-consumer recycled content
Minimal ink coverage to improve recyclability

Recyclability depends on local thin-film recycling streams. Documentation can be provided where applicable.

Operational Decision Factors

Before placing bulk orders, buyers typically evaluate:

Film thickness vs product weight
Custom sizing vs stock availability
MOQ flexibility
Lead time expectations
Artwork proof process
Bulk pallet shipping efficiency

Free USA shipping and free sample programs reduce testing risk before large production runs.

When to Combine Poly Mailers with Other Packaging

Poly mailers are often paired with:

Premium rigid formats such as Collapsible Rigid Boxes
Retail-ready formats like Custom Branded Boxes
Flexible inner packaging such as Resalable Mylar Bags
Specialty protection including Smell Proof Mylar or Vacuum Sealed Mylar Bags

This layered approach protects the product while optimizing freight.

Why Choose BoxBaba

BoxBaba manufactures custom poly mailers engineered for performance and scalability. What supports operational confidence:

Flexible MOQ based on customization level
Free Shipping Across USA
Free Samples with delivery reimbursed on first bulk order
Structured quality inspection before dispatch

For startups, SMBs and enterprise buyers, production consistency and repeat-order reliability are prioritized.

Start Your Order

To request a custom quote, confirm:

Required size
Quantity
Film thickness
Print requirements

Place your order by calling +1 305 574 4357 or emailing sales@boxbaba.com.

Frequently Asked Questions

Find all the urgent questions you may have.

What are custom poly mailers used for?

They are used to ship non-fragile items such as apparel, accessories, soft goods and secondary boxed products while reducing freight cost compared to corrugated packaging.

Are poly mailers cheaper than shipping boxes?

For lightweight products, poly mailers typically reduce dimensional weight and shipping expenses. Cost efficiency depends on size, film thickness and print requirements.

What thickness should I choose?

2–3 mil works well for apparel. Heavier goods may require 4–6 mil for added puncture resistance.

Can poly mailers be recycled?

Many mono-material poly mailers are recyclable through thin-film recycling programs. Recycling availability depends on local facilities.

Can I add return functionality?

Yes. Dual adhesive strips allow customers to reseal the mailer for returns.

Do poly mailers support inside printing?

Yes. Inside printing enhances branding and unboxing engagement.

What information is required for a quote?

Provide size, quantity, thickness preference and artwork file. Proof approval typically precedes production.

Custom Poly Mailers

4.3

Reviews 8 • Excellent

Andrew Diedrich

Date of experience:

Dec 2, 2025

Matt Lab

Date of experience:

Sep 19, 2024

Myralyn

Date of experience:

Feb 15, 2025

Hannah Ahmed

Date of experience:

Apr 26, 2025

Matteo

Date of experience:

Apr 29, 2025

Carol Scott

Date of experience:

Jul 9, 2025

Doug C

Date of experience:

Jul 15, 2025

Jess B

Date of experience:

Sep 10, 2025