Selecting the Right Mailer

What type of mailer is best for getting your materials safely into the hands of the recipient? Senders have options when it comes to mailers, including standard flat mailers, bubble mailers, poly mailers and even new eco-mailers. The right choice depends on several considerations, including cost, protection requirements, and how the mailer will be sent.

What Are Shipping Mailers?

Shipping mailers—sometimes called mailing bags or mailing envelopes—are a cost-effective and sustainable packaging choice for documents or smaller items, especially items that are flat, soft or foldable. A mailer looks like a large envelope or sleeve and may be made of kraft paper, plastic, cardboard or other materials. They are often self-sealing. They have become increasingly popular in the ecommerce shipping world, for everyone from small Etsy shops to large ecommerce sites like Amazon or Alibaba.

Advantages of Shipping Mailers

Shipping mailers offer significant advantages for many kinds of goods.

• Postage or shipping costs are usually cheaper for a mailer than for a box (sometimes significantly so). USPS, FedEx and UPS generally offer flat rate pricing for mailers.
• They use less material than a corrugated box, making them a sustainable choice for shippers who want to reduce their environmental footprint. New biodegradable and recyclable eco-mailers offer even better footprint reduction.
• Mailers do not require any void fill or packaging material, further decreasing costs and time.
• Many mailers are self-sealing for optimal efficiency on the packaging line—just stuff, seal and go, no added tapes or adhesives required.
• Mailers store flat and don’t take up much room on storage shelves.

What are shipping mailers used for?

Shipping mailers can be used for many mailing and shipping applications. They are best for items that are thin, lightweight and not overly fragile. Versatile poly mailers may also be used as final packaging for items that are already in a box of their own (such as shoebox or jewelry box). Mailers are commonly used for:

• Documents and paper items
• Clothing and apparel
• Books
• Jewelry and accessories
• School and office supplies
• Small parts and hardware

Types of Mailers

There are several types of mailers to consider, including poly mailers, bubble mailers, flat mailers, gusseted mailers and eco-mailers. Each type of mailer has its own strengths, weaknesses and typical applications.

What are flat mailers used for?

Self-sealing flat mailers may be made of cardstock, Kraft paper or thick white paper. They are a great alternative to a standard envelope for shipping papers and documents. They are best for items that are relatively flat, such as folders, thin books and booklets, and paperwork. They hold items flat, so papers do not arrive wrinkled or damaged. They may also be used for other flat items, but be careful not to overstuff the mailer. Because they are not gusseted, they may be prone to ripping at the edges if items inside are too thick. They are not waterproof, so if you are worried about water damage in shipment they may not be the best choice for you. However, they are an office essential for businesses needing to mail documents frequently. Flat paper mailers come in several standard sizes.

What are poly mailers used for?

Poly mailers are highly durable and versatile for shipping a wide range of goods. They are lightweight, flexible, waterproof and puncture-resistant, making them a favorite for shipping clothes and other soft goods. They can also provide protection for small boxed items such as shoes or electronics. Poly bags are highly economical both from a purchasing and a shipping perspective. They are self-sealing and easy to use, and they come in a variety of sizes from 7.5 x 10.5” to 24 x 24”.  There are also gusseted expansion mailers available, which are a good choice for shipping bulkier items like small pillows or clothes.

What are bubble mailers used for?

Bubble mailers combine the ease of an envelope with the protection of bubble wrap. They are available as either paper bubble mailers or poly bubble mailers in a variety of standard sizes. A standard bubble mailer is often the most economical packaging choice. The mailer is lined on both sides with a thin layer of bubble wrap, which provides additional protection for items inside. Padded bubble mailers (sometimes called padded envelopes) have an additional layer of padding, which makes them stiffer and harder to tear. Bubble mailers are a great choice for items that are a little more fragile, such as picture frames, artwork or jewelry. They provide more puncture resistance and shock absorption than a standard flat paper or poly mailer. However, keep in mind that they are not entirely crush-proof; highly fragile items may require more protection.

What are industrial mailers used for?

An industrial mailer is something in between a flat mailer and a corrugated box. They are made of corrugate and are self-folding, much like a pizza box. They provide additional crush protection not offered by other types of mailers. However, they may require some void fill if the item does not fit tightly into the mailer. These may be a good choice for shipping larger stacks of documents, thicker books, and small items that require more crush protection than provided by a bubble mailer.

What about eco-mailers?

Eco-mailers are a great option for companies wishing to further reduce their environmental footprint or address customer preferences for environmentally friendly packaging. Eco-mailers are made of a recyclable or biodegradable material and may be made of recycled materials themselves.

Can I get custom-printed mailers?

Yes! Some mailers come with custom-printing options. Custom-printed mailers allow you to put your brand on the package for better recognition. You can also have them pre-printed with your return address or special notices or messages for the recipient. Talk to us about custom printing options!

Mailers vs. Boxes

When should you use a mailer, and when should you use a box or shipping carton? Mailers are a great option for many shipping scenarios, but they are not right for everything. When choosing between boxes and mailers, consider what you are shipping, how much protection it requires, and the experience you want your recipient to have.

• Mailers are best for items that are soft, light and/or flat and require minimal protection during shipping. If the item can be safely shipped in a mailer, you can save significant money on both packaging and shipping costs. Mailers are also a more sustainable choice, since they use less material and take up less freight space.
• Boxes are a better choice for items that require crush protection. Highly fragile items are usually safer in a box with protective packaging material around them. Items that are sharp or irregularly shaped may also be better in a box, as they may be prone to puncture a mailer. Also consider the “unboxing” experience: do you want your recipient to have a luxury experience, opening a box that presents the product in a particular way? If presentation is important, a box gives you more options.

Saving Money with Mailers

Mailers help you save money on shipping and mailing in several ways.

• Mailers reduce shipping costs directly. Standard-sized mailers will qualify for flat mailing rates from major carriers including USPS, FedEx and UPS. This can save as much as 50% on shipping and mailing costs.
• Mailers are less expensive to buy than boxes because they use much less material. They also reduce the need for additional void fill materials. This provides considerable savings on packaging materials.
• Mailers improve packaging line productivity. Self-sealing mailers are fast and easy to use and do not require any special tools, training or additional materials.

Prices for mailers are impacted by the cost of raw materials and supply chain availability. To maximize your cost savings, use the right size and type of mailer for your items. Since mailers are economical to buy and don’t take up much storage room, you can easily stock several sizes and types. It’s best to outfit your packing station with the full range of sizes you may need.

• Pack your items in the smallest size mailer that will work, since postage rates are tied to the mailer size.
• Use the least expensive mailer that works for your application. The standard Kraft bubble mailer is usually the least expensive option.
• Buying in bulk may help you cut your costs further.

Keep in mind, though, cheaper is not always best. Very cheap mailers may be made of substandard-materials and may rip, tear or puncture more easily. It’s also important to make sure the mailer provides the right kind of protection for the item inside. If items arrive damaged, damage claims will be much more expensive than choosing the right mailer or box in the first place.

Understanding Mailer Sizing

Mailers come in a range of standard sizes. Mailer sizing directly impacts postage costs, so it usually makes sense to keep several different sizes in stock. Mailer sizes are given in either inches or in a number. The number system is convenient and easy for packaging line employees; instead of trying to remember an exact size, they can just say, “Give me a number 4!” Here is a mailer size chart for your convenience.

Mailer Size Chart

Find the Best Mailers for the Best Price

Benchmark sells a wide range of mailers of all types and sizes, including bubble mailers, standard flat mailers, poly mailers and industrial mailers. We stock high-quality mailers and other packaging materials at the best available price—if you find the same product at a cheaper price elsewhere, we will match or beat it.

Not sure which mailers are right for your shipping needs? Talk to a Benchmark packaging product expert today. Call us at 844-423-6246 or contact us online.