Custom Poly Mailers
Custom Poly Mailers for E-commerce, Apparel, and Fulfillment
Shop custom poly mailers made to match the realities of ecommerce shipping, from single-location apparel brands to mass merchandisers moving thousands of orders a day. Connover Packaging manufactures custom mailer bags in stock sizes from 3″ x 3″ up to 30″ x 48″, with full-color printing, permanent or reseal closures, and order minimums that work for businesses of any size. Request a Quote or see our poly mailer options below.
What Poly Mailers Are and Why E-commerce Runs on Them
Poly mailers are lightweight plastic shipping bags with a self-sealing adhesive lip that closes the package without tape, additional adhesives, or the bulk of a corrugated box. For e-commerce sellers shipping soft goods, books, health and beauty products, and lightweight merchandise, they have become the default choice for most order profiles.
The reasons are practical. A poly mailer weighs a fraction of a comparably sized box, which lowers the dimensional weight used to calculate shipping rates. It stores flat until packed, which saves warehouse space. It absorbs minor impact without collapsing. It accepts a shipping label directly on the face, so there is no need for separate pouches or adhesive sleeves.
And the self-sealing closure means fulfillment workers can pack and close each order in seconds, which matters when throughput is measured in units per hour.
Standard Poly Mailers
Single-layer custom poly bags for shipping the majority of e-commerce items. Clothing, accessories, books, soft goods, office supplies, and any product that does not need cushioning protection fit this category. Available in clear films when you want the contents visible to fulfillment and returns teams, or opaque films when privacy is a selling point for your customers.
Bubble-Lined Mailers
For products that need impact protection without the weight of a box, bubble-lined poly mailers combine an exterior shipping film with an integrated bubble wrap layer. These are used for electronics, cosmetics in glass containers, ceramics, and any item where a drop from the porch step would otherwise be a problem.
Returns and Reseal Mailers
Apparel and footwear customers expect easy returns, and a mailer with a second adhesive strip lets them reseal the same bag to send the order back. This reduces your returns processing cost and the environmental footprint of a second bag being produced for every return.
Flat Poly Bags for Shipping
When you need a simple flat bag without the mailer’s self-sealing lip, our flat poly bag line covers those applications. Common uses include inner product bagging before the outer mailer goes on, protective wrapping for apparel during transit, and fulfillment workflows where a tape seal or heat seal is preferred over adhesive.
Large-Format Shipping Bags
Custom shipping bags up to 30″ x 48″ for oversized soft goods such as bedding, curtains, coats, pillows, and bulk apparel orders. Heavier film weights handle the additional product mass without risk of punctures or tears in the USPS, UPS, and FedEx handling environment.
Sizing Range
Custom mailer bags are available in sizes from 3″ x 3″ for small items such as jewelry, accessories, and cosmetics samples, through 30″ x 48″ for bulky soft goods and large apparel orders. Common e-commerce sizes in between include 6″ x 9″, 9″ x 12″, 10″ x 13″, 12″ x 15.5″, and 14.5″ x 19″, which, between them, handle most apparel, book, and consumer goods shipping profiles.
During quoting, we help you match mailer size to your actual product mix so you are not paying for air space or forcing oversized items into undersized bags.
Custom Printing for Brand Experience
The box opening, or in this case, the mailer opening, is part of the product experience for e-commerce customers. A branded mailer sets a different tone than a blank generic bag, and for direct-to-consumer brands, that tone is often the first physical impression a customer gets of the company.
Our custom printed poly mailers support:
- Up to six custom colors with PMS matching to your brand palette
- Full-bleed printing across the entire bag face
- Front-and-back designs with different artwork on each side
- Logos, custom illustrations, taglines, and photographic imagery
- White ink printing on colored or kraft-tone films
- Custom interior prints that show when the customer opens the bag
Our in-house design team can reproduce your existing logo from files or a physical sample, or work with you to develop new artwork if you are launching a brand or refreshing an existing look. If you are migrating from another vendor, most art files transfer directly.
Why Businesses Choose Poly Mailers Over Boxes
Packaging products has never been simpler. Here’s why more businesses are reaching for poly mailers:
- Lower shipping cost: Poly mailers weigh a fraction of a comparably sized corrugated box, which reduces the billable weight carriers use to calculate rates. For high-volume shippers, that difference compounds into annual savings.
- Lower storage footprint: Mailers ship and store flat until packed. You can stock tens of thousands of bags in the space a few hundred boxes would occupy, which matters in small fulfillment centers and 3PL operations.
- Faster fulfillment: Self-sealing closures eliminate the need for taping. Packers move through orders faster, increasing throughput and lowering labor cost per unit.
- Better fit for mailbox delivery: Slim mailer profiles fit inside standard mailboxes for most residential carriers, which reduces porch theft risk and improves customer satisfaction.
Get a Quote on Custom Printed Poly Mailers for Your Shipping Program
Whether you are shipping a few hundred orders a week from a home studio or running a multi-warehouse fulfillment operation, we can quote custom poly mailers that fit your volume, product mix, and brand standards. Request your quote or call 1.800.770.4906 to talk with an account manager who understands e-commerce shipping.
Frequently Asked Questions About Custom Poly Bags for Shipping
Yes. Poly mailers are accepted by USPS International, UPS Worldwide, FedEx International, and DHL for items that meet each carrier’s size and weight requirements. For international routes with extended transit or rough handling, we recommend heavier-gauge films or bubble-lined mailers for products that could be damaged by compression or drops.
Keep them flat, out of direct sunlight, and in a temperature-controlled space. Prolonged UV exposure degrades the adhesive on the self-sealing lip, and extreme heat can cause the adhesive strip to activate prematurely. A standard warehouse environment is fine, but avoid storing them against exterior walls that get hot in summer or near loading bay doors.
Yes. For ecommerce categories where tamper-evidence matters, such as cosmetics, supplements, electronics, and higher-value apparel, we build mailers with tamper-evident closures adapted from our SECUR-PAK line. These reveal visible signs of any attempt to open the bag in transit.
