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.

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Custom Poly Mailers for Secure & Branded Shipping

Enhance your brand presence with high-quality custom poly mailers designed for secure, lightweight, and cost-effective shipping.

What We Give

Create Custom Boxes Quick and Easy

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:
  1. Folded product dimensions
  2. Desired packing tolerance
  3. Film thickness requirement
  4. 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.

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.
For lightweight products, poly mailers typically reduce dimensional weight and shipping expenses. Cost efficiency depends on size, film thickness and print requirements.
2–3 mil works well for apparel. Heavier goods may require 4–6 mil for added puncture resistance.
Many mono-material poly mailers are recyclable through thin-film recycling programs. Recycling availability depends on local facilities.
Yes. Dual adhesive strips allow customers to reseal the mailer for returns.
Yes. Inside printing enhances branding and unboxing engagement.
Provide size, quantity, thickness preference and artwork file. Proof approval typically precedes production.

Get a Custom Quote