Custom Poly Mailer Buying Guide
What Are Custom Poly Mailers?
Custom poly mailers are lightweight, flexible shipping envelopes made from polyethylene film, printed with your business logo, brand colors, and messaging. Unlike plain poly mailers, custom versions transform every shipment into a branded unboxing experience that reinforces your identity and builds customer loyalty.
Key Features & Benefits
Tamper-Evident Security: Self-sealing adhesive strips create a permanent seal. Any attempt to open leaves visible damage, protecting both you and your customers from tampering or fraud.
Water-Resistant Protection: Polyethylene construction shields contents from rain, snow, and spills during transit. Your products arrive dry and undamaged.
Tear & Puncture Resistant: Co-extruded film withstands rough handling during shipping. Available in multiple thicknesses (2.5 mil to 3.5 mil) for different product weights.
Lightweight = Lower Shipping Costs: Poly mailers weigh a fraction of cardboard boxes. Reduce dimensional weight charges and save on every shipment.
Easy Storage: Flat, flexible mailers take up minimal warehouse space compared to bulky boxes. Store thousands in the space of a few cartons.
Custom Printing Options
We offer full-color flexographic printing with up to 4 colors. Print your logo, tagline, social media handles, return address, or promotional messages. Choose from:
- Full exterior coverage for maximum brand impact
- Simple logo + tagline for clean, professional look
- Interior printing for surprise-and-delight unboxing
- Multiple designs for seasonal campaigns or product lines
Size Guide
Choose the right size based on your product dimensions. Mailers should have 1-2" of clearance on all sides:
- 6x9": Jewelry, cosmetics, small accessories
- 9x12": T-shirts (folded), books, phone cases
- 10x13": Clothing, shoes (small), multiple items
- 12x15.5": Sweatshirts, jeans, small electronics
- 14.5x19": Large apparel, boxed products, bulk orders
- 19x24": Coats, bedding, oversized items
Minimum Order Quantities (MOQs)
We offer flexible minimums to fit businesses of all sizes:
- Standard MOQ: 5,000 pieces per size/design
- Lower MOQs available for multi-size or test orders - contact us for details
- Need stock mailers? Check our stock poly mailers with no minimums
Turnaround Time
Production typically takes 2-3 weeks after artwork approval. Rush service available for urgent orders. Need faster? Our stock poly mailers ship same-day.
FDA-Safe & Eco-Friendly
All our poly mailers are FDA-compliant for indirect food contact, making them safe for cosmetics, supplements, and packaged food items. LDPE material is recyclable at most store drop-off locations.
Industries We Serve
- E-commerce & online retail: Branded shipping for Shopify, Amazon FBA, Etsy sellers
- Subscription boxes: Consistent branding month after month
- Apparel & fashion: Professional packaging for clothing brands
- Beauty & cosmetics: FDA-safe for product contact
- Health & wellness: Tamper-evident for supplement fulfillment
Why Choose Prism Pak for Custom Poly Mailers?
- Wholesale pricing: Direct manufacturer pricing, no middleman markup
- Free samples: Test before you commit to a production run
- Expert support: Our team helps with sizing, design, and ordering
- Fast turnaround: In-stock materials = quicker production
- Quality guarantee: Every order backed by our satisfaction promise
Custom Poly Mailers: Frequently Asked Questions
What is a custom poly mailer?A custom poly mailer is a lightweight polyethylene shipping envelope printed with your logo, brand colors, and messaging. It has a self-sealing adhesive strip, is water-resistant and tear-resistant, and replaces a cardboard box for soft or lightweight goods such as apparel, books, and cosmetics. What sizes do custom poly mailers come in?Custom poly mailers are available from 6x9" up to 24x24". Common sizes are 6x9" for jewelry and cosmetics, 9x12" for folded t-shirts and books, 10x13" for clothing and small shoes, 12x15.5" for sweatshirts and jeans, 14.5x19" for large apparel, and 19x24" for coats and bedding. Allow 1-2" of clearance on all sides of your product. How thick are custom poly mailers?Custom poly mailers are made from co-extruded film in thicknesses from 2.5 mil to 3.5 mil. Lighter 2.5 mil film suits soft goods like apparel, while 3.5 mil is recommended for heavier products or items with edges that could puncture thinner film. Are custom poly mailers food safe?Yes. Our poly mailers are FDA-compliant for indirect food contact, which makes them suitable for shipping packaged food items, supplements, and cosmetics. For direct food contact, use an FDA-approved poly bag or pouch rather than a mailer. What is the minimum order for custom printed poly mailers?The standard minimum order is 5,000 pieces per size and design. Lower minimums are available for multi-size or test orders - contact us for details. If you need smaller quantities right away, our stock poly mailers have no minimum and ship same-day. How long does it take to get custom poly mailers?Production takes 2-3 weeks after artwork approval. Rush service is available for urgent orders. A digital proof is provided for your approval before printing begins, and stock (unprinted) poly mailers ship same-day if you need product sooner. Can I order multiple sizes with the same design?Yes. We can print the same design across multiple mailer sizes, and each size counts toward the total minimum order quantity. This lets you keep consistent branding across a full range of product sizes without a separate MOQ for each one. What artwork file format do you need for custom printing?Vector files (AI, EPS, or PDF) are preferred. High-resolution PNG or JPG files are accepted subject to design review. Printing is full-color flexographic with up to 4 colors, and we offer basic layout assistance plus professional design services for more complex projects. Are poly mailers recyclable?Yes. LDPE poly mailers are recyclable at most grocery store plastic film drop-off locations, the same bins that accept plastic grocery bags. They are generally not accepted in curbside recycling, so check your local program before disposal. Are poly mailers cheaper to ship than boxes?Usually, yes. A poly mailer weighs a fraction of a comparable cardboard box and takes up far less volume, which lowers both actual weight and dimensional weight charges on every shipment. Flat mailers also cut warehouse storage space compared to bulky cartons. Ready to Get Started?
Request a free sample to see and feel the quality for yourself, or submit a quote request below with your size, quantity, and design details. Our team will respond within 24 hours with pricing and next steps.
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