Protective Mailers

What it is

Mailers ship small items without a box. They save space, weight and dimensional weight charges. The main types are:

• Bubble mailers: a bubble lining inside a kraft paper or poly film outer.
• Padded paper mailers: paper envelopes with a layer of recycled paper padding or a paper-based cushion.
• Poly mailers: flexible plastic envelopes with no cushioning, often co-extruded white outside and gray or black inside for opacity.
• Rigid mailers: stiff paperboard envelopes for documents and photos that must not bend.

How to identify

Feel the inner surface. Bubble lining is easy to see. Padded paper mailers feel thick and soft with no bubbles. Poly mailers are thin film with no padding. Most have a peel-and-seal adhesive strip. Some have a second strip for return shipping. Mailer sizes are labeled by inside dimensions and often by a size number; check the inside dimensions, because size numbers can differ by maker.

Mailer types compared

Key points

• Mailers suit small, sturdy items. Breakables need a box with cushioning.
• Measure the item thickness. A thick item needs extra length and width to fit in a flat mailer.
• Tamper-evident adhesive shows if the mailer was opened.
• Carriers charge by weight and size. A mailer can avoid box dimensional weight charges.
• Recycled content and curbside recyclability claims should be checked on the maker's data sheet.

Common mistakes

• Shipping glass or ceramics in a bubble mailer.
• Ordering by size number without checking inside dimensions.
• Overstuffing so the seal opens in transit.
• Using poly mailers for sharp-edged items that can puncture the film.

Governing standards: No single product standard. Carrier packaging and mailable item rules; FTC Green Guides for recyclability claims.

Reference only. Verify against the current governing code or standard, the manufacturer's data and the project documents before use. Apps for Distributors disclaims liability arising from reliance on this reference.