Bubble Mailers

We’re upgrading our bubble mailers to a new, more sustainable film blend. The biggest shift? A significant increase in recycled content — from 50.27% to 60–62% — marking a meaningful sustainability improvement.

Both films are RCS Blended Certified, but our new film is printed with the RCS Blended Certification logo, which verifies the recycled inputs in the mailer and represents a higher level of sourcing transparency and accountability.

Our new film is also light grey in color, whereas our original film is white.

Want to dive deeper? Learn more about RCS and our recycled content standards

A bubble mailer is a cushioned mailer envelope made of polyethylene film. It has a layer of bubbled air pockets and is made from plastic, making it waterproof. These cushioned mailers are designed to protect fragile items in transit.

Those made of plastic are recyclable with thin film (#2 and #4 stretch film plastics). Many consumers have access to thin film recycling at local grocery stores. Curbside recycling is not widely available.

Check out our Ultimate Guide to Protective Mailers for more information.

Today, most bubble shipping envelopes and bags are made with virgin content.

Other "eco-friendly" alternatives exist but generally have less recycled content and/or unverified figures. For example, they may claim 100% recycled content, but a further inquiry reveals that only the outer layer has high levels of recycled content. There are kraft exterior/plastic interior cushioned mailers that may have some recycled content but are unrecyclable and must be landfilled. Finally, those described as "degradable" and "compostable" are emerging but do not meet our strict standards for sustainable packaging. Read more about our Stance Against Degradable Plastics and our Perspectives on Bioplastic Ecommerce Packaging.

All of this said, we fully recognize that 50% recycled content falls short of our long-term vision. While we’re still striving to develop a 100% recycled version, we have found our 50% recycled version to be the best option, given manufacturing and shipping constraints. They have nine film layers, and the complex manufacturing process is highly partial to the purity and consistency of virgin content.

Check back often to see what kinds of developments we come up with because we’re always looking to improve our products. For example, we launched with 32% recycled content, and within two years, we released 50% recycled content. And this 50% recycled option has 10% post-consumer waste. That is real, measurable progress.

Sustainability isn’t just about the material — it’s about right-sizing, damage reduction, and overall material use. A durable mailer that prevents reships can reduce total environmental impact. For a broader framework on evaluating protective packaging, EcoEnclose’s Definitive Guide to Protective Mailers offers helpful context.

The terms bubble mailers and bubble envelopes are often used interchangeably. Both refer to mailers with a padded interior designed to protect items in transit. At EcoEnclose, bubble mailers are designed for durability, moisture resistance, and reduced material waste compared to box-and-void-fill combinations.

Padded and bubble mailers are very similar in that they offer cushioned, protective packaging for your shipped products. The main difference is the material: padded mailers typically have a soft, cushioned interior made from paper, while bubble mailers have an air-filled interior made from plastic.

Our padded mailers are paper-based with macerated newsprint.

• They are made with 100% recycled paper of which 20% is made with post-consumer recycled content
• Their structure makes them easy to recycle because the vast majority of curbside programs accept them
• They are naturally biodegradable outside of the plastic tear strip, which is removed when a customer opens the package
• They can be printed with custom designs for low-volume orders of 500 units

Our bubble mailers are plastic-based with air pockets.

• They are made with 50% recycled plastic, of which 10% is post-consumer content
• They are thin-film recyclable, however, they are downcycled into composite lumber (versus recycled back into packaging)
• They are weather-proof
• They are lighter and more compact, which can help keep shipping costs—and your environmental impact—down
• They are less expensive
• They have a lower carbon footprint*.

*This is because much less material is needed to achieve the same functionality. This is true in almost all cases when comparing paper versus plastic packaging - paper is more circular, but plastic is typically more carbon efficient.

The main difference is that a bubble mailer is a lightweight, small padded envelope, while a shipping box is a cardboard container intended for packing and shipping larger or more fragile items.

Bubble mailers work best for lightweight, fragile, or scratch-prone items that don’t require rigid structure. If you’re shipping heavier products, sharp edges, or items that could deform under pressure, a box may offer better protection. EcoEnclose’s guide on choosing between a mailer or a shipping box walks through these tradeoffs in more detail.

Prices for bubble mailers and shipping boxes can vary depending on the type, size, and quantity you need. However, per unit, bubble mailers are often less expensive than shipping boxes.

For small businesses with less shipping needs, bubble mailers are an excellent option for lightweight and speedy shipments. Shipping boxes may be more appropriate for larger products but require more cost and effort to pack and ship.

EcoEnclose carries four bubble mailer sizes. Below is a list of typical items that can fit in each.

• 4 x 6.75" - jewelry or small vials of cosmetics and oils
• 6.5 x 8.75" - larger jewelry items, wallets, larger cosmetic items, and small clothing items
• 8.5 x 10.75" - small to medium clothing, books, journals, small clutches and handbags, picture frames
• 10.5 x 15" - medium clothing, larger books, some framed prints

To select the best bubble mailer sizes for your needs, we recommend laying out the items you will be shipping on a table and measuring the imaginary bounding box it would fit in. The two dimensions of your selected mailer must exceed the largest two dimensions of your products' bounding area, plus a little extra room to compensate for the mailer's expansion when it’s filled.

Once you've selected, order a free sample to test them. One of the worst feelings in the world is ordering everything you need to start shipping your product and finding out that what you thought was perfect is actually too small to ship your items. We want to avoid any issues with our bubble envelopes, so we encourage people to use our samples to test.

Yes, custom mailers are available starting at 25,000 units. Our inline production process delivers the best results, producing brighter colors and crisper lines that help your brand stand out from the moment a package arrives.

If you don’t need the volume required for inline printing, you still have great options. Our stock mailers feature distinctive, eye-catching designs that naturally signal your sustainability values. Many brands also pair them with eco-friendly custom stickers, which offer significantly lower minimum order quantities while still making your packaging feel intentional and on-brand.

You can learn more about branding options and artwork considerations on the Custom Branding resource page.

Yes. Custom bubble mailers can carry your branding while still delivering protection in transit. For many brands, the mailer is the first physical touchpoint with a customer. EcoEnclose’s Custom Branding resource outlines how to approach artwork, print methods, and design considerations without compromising performance.

Featuring two adhesive strips, businesses use the upper strip before shipping, and customers use the lower strip for a second seal when making a return or sending out their items to loved ones.

Made with recycled content and thin film recyclable, the outer is #4 LDPE plastic, and the inside is #2 LDPE plastic. A small but growing set of curbside recycling programs accept them; recipients can check with their waste management provider to confirm. However, most curbside programs do not currently accept them because the bags are too thin to be effectively sorted by equipment in most MRFs.

So instead, you can recycle these the same way you would recycle grocery bags, typically by taking them to a grocery store that collects and recycles these plastics. You can use the zip code locator here to find a participating store.

We also have a poly film take-back program for any customers you work with that don’t have access to thin film recycling. We simply ask that individuals stuff these mailers full of poly film before sending them back to help manage the carbon footprint of shipping it back and allow these mailers to serve as vehicles to get even more poly film into the recycling stream.

Our Guide to Thin Film Recycling and How2Recycle® Labeling is designed to help you navigate the nuance of thin film in your packaging.

They can, when they’re the right fit. Bubble mailers often replace a box plus void fill, which can mean less total material, lower shipping weight, and fewer damaged shipments. Choosing the right size and strength is key. If a mailer prevents reships or excess packaging, it can reduce overall waste even when recycling options vary.

Yes. Bubble mailers are designed to be water-proof, helping protect contents from moisture during shipping. This makes them a strong choice for items that need both cushioning and protection from rain or spills.

Bubble mailers are designed to handle the bumps and jostles of standard shipping. The cushioned interior helps protect against impacts, while the outer layer resists tearing and moisture. That said, durability depends on choosing the right size and using them for items that don’t require rigid structure.