Mailers

EcoEnclose uses the term mailer to describe a shipping envelope to package and send products ranging from soft textiles and durable goods to art prints and documents. Mailers are available in various materials but are most commonly offered in plastic and paper. These shipping solutions feature a self-sealing adhesive strip to seal the mailers or may feature tabs that require packing tape for a secure seal.

For many brands, this is the first packaging question they work through. Check out our detailed post: Choosing Between and Mailer or Shipping Box.

Here’s a quick summary: If you can successfully ship your orders in mailers, we recommend them over boxes. They are less expensive, use less material (making them more sustainable), are more operationally efficient, and are easier for your end customers to work with. Mailers are successful for brands that ship products like apparel, books, picture frames, wallets, sunglasses, cosmetics, jewelry, and essential oils. However, stick with shipping boxes if you ship bulky, heavy, fragile, oddly shaped items or a varied collection.

There is considerable debate regarding paper versus plastic in the packaging and sustainability world. The question we get most frequently? Should I use recycled paper or plastic packaging if I try to be as eco-friendly as possible?

It isn’t an easy answer. Paper is made from renewable resources. Our paper mailers and corrugated boxes are recyclable and made from 100% recycled material. In the worst-case scenario, when left as litter, the material will biodegrade.

But recycled plastic does have its advantages. A 100% recycled poly mailer is more energy efficient to produce and has a significantly lower carbon footprint than paper. Plastic mailers are lighter than paper counterparts, so shipping things in poly mailers is more energy efficient. Additionally, recycled poly mailers are cheaper than paper alternatives, giving cost-focused brands a chance to make a sustainable leap forward without breaking their budget.

When it comes to eCommerce packaging, there is no perfect answer. First, consider what you need to ship and how to protect it in transit and present it to your customer. Next, consider your sustainability goals and eco framework. If you are focused on minimizing carbon, recycled plastic may be optimal. Paper may be preferred if you are focused on ease of recyclability or natural biodegradability. Please ensure your paper solutions are 100% recycled or have as much recycled content as possible. If they are virgin, skip any paper from non-certified sources. Learn more: All Paper Isn’t Equal.

We offer many mailers, and consider all to be strong sustainable packaging choices, but they each serve a unique purpose. Read on to understand the differences between these mailers and their ideal use case.

Poly Mailers: Ideal for soft goods (apparel, textiles, etc.) and, in some cases, can be used to ship boxed items that need an outer layer, like shoes, prints, and stationary. Don’t use poly mailers when sending different products in the same package. For example, if you want to ship a t-shirt, wallet, and bottle of lotion, it’s probably better to use a box. In addition, lumpy dimensions can make the mailers hard to scan en route, causing shipping delays. Learn more about when to use poly mailers and how to choose between different options.

Kraft Mailers: An entry-level paper-based mailer that ships lightweight apparel, other soft goods, documents, and other thin, flat items.

EcoX Mailers: Very similar to our Kraft Mailer, but a bit thicker. They also contain less post-consumer waste - 70% compared to 90%+ for our other mailers in this category; the remaining 30% is post-industrial waste. This higher level of post-industrial waste leads to a stronger mailer. They are also surprisingly water resistant and are a great alternative to the poly mailer.

Apparel Mailers: Designed to be a strong, sturdy alternative to poly mailers for shipping apparel and bulky outdoor gear. It is an excellent mailer for backpacks, jackets, and other thick clothing or for brands that want to deliver a premium, high-end experience.

Padded Mailers: These cushioned, paper-based mailers protect whatever you are shipping. Great for accessories, books, accessories, sunglasses, essential oils, supplement bottles, etc.

Bubble Mailers: These cushioned poly-based mailers serve the same purpose as padded mailers but are a 50% recycled, thin film recyclable, waterproof alternative.

Rigid Mailers: Designed to stay flat and unbent in transit, and are a great solution for shipping prints, photos, and other art. We offer a self-sealing (thinner) option and a tab-locking (thicker) option.

Reusable Mailers: Designed to go through dozens and dozens of cycles in the mail, and are an excellent shipping solution for businesses with returns baked into their business model - such as clothing subscription brands.

Flat mailers are those with three side seals, without cushioning, that lay flat when empty. Flat mailers are the most common and work excellently in most contexts.

Protective mailers - bubble mailers, padded mailers, cushioned mailers - describe mailers with cushion or padding inside. This padding serves two purposes - it offers some protection and enables the mailer to hold its shape, regardless of what it contains.

Gusseted mailers expand on the sides, which makes for more efficient fulfillment operations because they are easier to fill than flat mailers. Gussets also allow bulkier goods like jackets to be more easily packaged. However, a drawback of gussets is that it is tempting to overstuff these mailers, creating more opportunities for tears and damages in transit.

We are thrilled to offer the ReEnclose Reusable Mailer. These mailers are made with rPET recycled polyester and are designed to be used dozens of times. Because your customers need to ship them back to you so you can reuse them, we recommend exploring these if your brand has returns baked into the business model. We’ve seen these work successfully for subscription clothing rentals, testing companies, and companies with take-back programs.

We offer six paper mailer solutions, three specifically designed for apparel. Why so many? Transitioning from plastic to paper can be challenging for brands. Different paper thicknesses and mailer constructions allow brands to find the most successful plastic-free solution for their needs.

Check out our primary guide - Which Paper Mailer Is Right For My Business?

Yes - Our mailers can be custom branded at standard MOQs of 500 and special minimum order quantities of 250.

Learn about custom branded mailers here.
Learn about our mailer artwork guidelines here.

Mailers are printed post-production when ordered at volumes of 5,000 or fewer units. At higher volumes of 5000 for some mailers and up to 25,000 for others, mailers are printed inline. Many of our mailers can also be offered in custom sizes and constructions at these high volumes. If you want high-volume customization, check out our Enterprise Capabilities.