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All padded envelopes fall into five categories. While each offers protection, their environmental impact varies dramatically. Understanding materials + end-of-life is the key to choosing wisely.

1. Bubble Envelopes with Plastic Exterior & Plastic Cushioning

Eco-rating: ★★★★☆ (when done right)
End-of-life: Thin-film recyclable (store drop-off)

These mailers are made entirely from polyethylene (typically HDPE #2 and LDPE #4) and—if free of foil or metalized layers—can be recycled anywhere plastic bags are accepted.

Most options on the market are still made with 100% virgin plastic, but recycled-content versions represent a meaningful step forward.

What to look for:

• Verified, consistent recycled content across all layers

• Clear disclosure by layer (outer film vs. bubble vs. cap)

• Recyclability without added foils or coatings

Beware of vague claims like “up to 30% recycled content.” Often this applies only to part of the exterior layer, meaning the actual recycled content of the full mailer may be far lower—and inconsistent from batch to batch.

We are proud to offer a plastic bubbled envelope - the Bubble Mailer - with industry-leading 60% recycled content and 10% post-consumer waste.

2. Bubble Envelopes with Paper Exterior & Plastic Cushioning

Eco-rating: ★☆☆☆☆ (avoid these)
End-of-life: Not recyclable

These hybrid mailers bond plastic bubbles to kraft paper, making them impossible to recycle. Despite this, they’re frequently (and incorrectly) labeled as recyclable, leading to widespread contamination in paper recycling streams.

They’re also typically made with virgin materials and offer no real sustainability upside. The paper exterior may look greener—but it creates real downstream harm.

3. Padded Envelopes with Paper Exterior & Paper Cushioning

Eco-rating: ★★★★☆ (varies by design)
End-of-life: Curbside recyclable

Paper-based padded envelopes avoid plastic entirely (or nearly so) and can be recycled in standard curbside systems. Sustainability varies based on:

• Cushioning efficiency (how much material is used)

• Percent post-consumer recycled content

• Responsible sourcing of any virgin paper inputs

Options include layered recycled paper, macerated paper fill, embossed paper “air” structures, honeycomb paper, and corrugated fluting. Many on the market are still made with 100% virgin paper, so recycled content should be prioritized whenever possible.

Paper isn’t automatically better than plastic—material efficiency and real-world recyclability matter. The most sustainable choice depends on product weight, protection needs, and shipping distance.

Explore our envelopes in this category - Padded Mailer with a mascerated paper cushioning layer and Paper Bubble Mailer with an embossed paper layer.

4. Padded Envelopes with Paper Exterior and Expanded Adhesive Cushioning

Eco-rating: ★★★☆☆
End-of-life: Curbside recyclable

Made popular by Amazon, these envelopes are two layers of kraft paper that sandwich a unique cushioning layer made from components commonly used in glue for corrugated boxes. An additive is added that will expand the glue when heated in the ovens during the converting process.

The cushioning material is so minimal that it does not affect the mailer's recyclability and is readily separated from the paper fibers during repulping.

Our sustainable version of this envelope - the EcoTec Mailer - is made with 100% recycled kraft paper fiber and 25% post-consumer waste.

5. “100% Biodegradable” Bubble Mailers

Eco-rating: ★☆☆☆☆ (avoid these)
End-of-life: Not recyclable; often industrially compostable only

Biodegradable plastic envelopes are typically made from virgin materials and rely on disposal pathways that most consumers don’t have access to. Worse, biodegradability claims often confuse people, leading them to place them in recycling or compost streams—where they don’t belong and can cause damage.

Until disposal systems and labeling catch up, these materials create more problems than they solve.

Bottom Line

• Best plastic option: Fully recyclable plastic bubble mailers with verified recycled content

• Best paper option: Curbside-recyclable padded paper mailers with high post-consumer content

• Avoid: Paper–plastic hybrids and biodegradable plastics with unclear end-of-life paths

Sustainability isn’t about appearances—it’s about honest materials, transparent claims, and real-world outcomes.

Click to enlarge. Source: EcoEnclose

Click to enlarge. Source: EcoEnclose

Click to enlarge. Source: EcoEnclose

The Pros of Padded Envelopes

The Pros of Shipping Boxes

By flat mailers, we refer to paper and poly-based mailers with no cushioning. They have no protection, are flimsier, and don’t hold their shape.

The Pros of Padded Envelopes

They have the added protection of a plastic bubble liner or, like our 100% Recycled Paper Padded Mailers, a layer of 100% post-consumer waste macerated newsprint.

They are ideal for shipping items that cannot fill out a flat mailer such as a tub of lipstick or a glasses case.

The Pros of Flat Mailers

They are less expensive per unit and are cheaper to ship to your facility and to your customers.

They are significantly thinner, making shipping and storage far more cost and environmentally efficient.

There’s no single “best” padded envelope—only smarter choices based on priorities.

Plastic bubble envelopes and paper-based padded envelopes each involve trade-offs in terms of functionality, environmental impact, and cost. Below is a clear comparison of where each option shines.

Recycled Content

Winner: Paper-Based Padded Envelopes

Paper-based padded envelopes have more recycled content than their plastic counterparts.

Our EcoTec Mailers and Padded Mailers are made with 100% recycled content, including post-consumer kraft paper and macerated newsprint. Our Bubble Mailers are made with 60% recycled content, with 10% post-consumer waste.

That said, reaching 60% recycled content in a high-performance bubble mailer is a major technical achievement. Choosing recycled plastic mailers helps fund continued innovation—and moves this ubiquitous packaging format closer to a fully circular future.

End-of-Life & Recycling

Winner: Paper-Based Padded Envelopes

Most paper and plastic envelopes are recyclable, but accessibility differs.

• Paper-based padded envelopes are accepted by nearly all US curbside recycling programs.

• Plastic bubble mailers must be recycled via store drop-off (where plastic bags are accepted), which is widely available but less intuitive for consumers.

Paper-based envelopes come out ahead due to curbside convenience.

Our paper-based EcoTec Mailers, Padded Mailers, and Paper Bubble Mailers are widely accepted in curbside recycling programs in the US.

Reusability

Winner: Plastic Bubble Envelopes

Both formats can be reused, but plastic bubble mailers, like our Bubble Mailers, are purpose-built for it. Features like dual peel-and-seal closures, tear strips, and on-mailer reuse messaging make reuse easy for returns or secondary shipments.

Paper-based padded mailers can be reused, but typically require folding and taping—adding friction that reduces real-world reuse rates.

A Critical Caveat: If Mailers Go to Landfill

This is where the comparison becomes more complex.

If neither mailer is recycled and both end up in a landfill, paper-based padded mailers can have a worse climate impact than plastic bubble mailers:

• Recycled paper can leach contaminants as it breaks down

• Paper degrades anaerobically, producing methane—a greenhouse gas far more potent than CO₂

• Methane is 84× more potent than CO₂ over its first 20 years and 21× over 100 years, per EPA data

Paper breaking down is desirable in compost systems—but not in landfills, especially those without effective methane capture.

Bottom Line

• Choose paper-based padded mailers when curbside recyclability and maximum recycled content are top priorities—and when you’re confident recipients will recycle.

• Choose plastic bubble mailers when durability, reuse, and real-world recycling via store drop-off are more likely outcomes.

Sustainability isn’t about material type alone—it’s about what actually happens after delivery.

Beyond recycled content and disposal, padded envelopes differ meaningfully in how they’re made, shipped, stored, used, and priced. These “rest-of-life” factors often tip the scale.

Overall Environmental Impact

Winner: Plastic Bubble Envelopes

When comparing same-sized mailers, plastic bubble envelopes generally have a lower total environmental footprint than paper-based padded envelopes. Paper options require significantly more material and weight, which increases emissions from raw material extraction, manufacturing, and transportation—even when recycled inputs are used.

Lifecycle analyses consistently show that heavier, material-intensive paper envelopes tend to generate higher carbon emissions, carcinogens, and ecotoxicity than lightweight poly alternatives.

Weight, Space & Logistics

Winner: Plastic Bubble Envelopes (sometimes)

Plastic bubble envelopes, like our Bubble Mailers, are lighter and more space-efficient than a bulkier paper-based padded envelope, like our Padded Mailers.

• ~⅓ the weight of comparable paper-based padded mailers

• Require far less warehouse space

• Allow more units per pallet and per shipment

These efficiencies reduce inbound freight emissions, storage costs, and outbound shipping impact—benefits that compound at scale.

However, some paper-based padded envelopes, like our EcoTec Mailer and Paper Bubble Mailer, offer light cushioning without the bulk and are more compact than a traditional plastic bubble envelope. Choose the right mailer depending on how much cushioning you need for your product.

Rigidity & Protection

Winner: Paper-Based Padded Envelopes

Thicker paper-based padded envelopes, like our Padded Mailers, are stiffer and better suited for items that shouldn’t bend. If rigidity is essential, they outperform flexible poly mailers. That said, for truly unbendable protection without cushioning, rigid mailers are often the better solution.

Not all paper-based padded envelopes are equal. Some are specifically designed with less rigidity, like our EcoTec Mailer, for those brands that only need light product protection.

Weather Resistance

Winner: Plastic Bubble Envelopes

Plastic bubble envelopes, like our Bubble Mailers, are fully moisture-resistant, offering better protection in wet conditions. In practice, weather rarely poses an issue for eCommerce shipments, as most orders already rely on paper-based outer packaging.

Aesthetic & Branding

Winner: Depends on Your Brand

Paper-based padded envelopes offer a natural, kraft-forward look and allow custom printing at relatively low volumes.

Plastic bubble mailers lean sleek and modern; while custom printing requires higher minimums, stock designs can still signal sustainability and elevate the unboxing experience.

Cost

Winner: Plastic Bubble Envelopes

For equivalent sizes, plastic bubble envelopes are generally more affordable due to lower material usage, lighter weight, and more efficient manufacturing.

Bottom Line

• Plastic bubble envelopes excel on total lifecycle impact, weight, durability, reusability, weather resistance, and cost.

• Paper-based padded envelopes win on rigidity, curb appeal for kraft-forward brands, and compatibility with curbside recycling systems.

The most sustainable choice depends on how your packaging is used, shipped, reused, and ultimately handled—not just what it’s made of.