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 plain 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-approved 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
Frequently Asked Questions
Can I order multiple sizes with the same design?
Yes! We can print your design across multiple sizes. Each size counts toward the total MOQ.
Do you provide design services?
We offer basic layout assistance. Professional graphic design services available for complex projects.
What file format do you need for artwork?
Vector files (AI, EPS, PDF) preferred. High-resolution PNG/JPG accepted with design review.
Can I see a proof before production?
Absolutely. We provide a digital proof for approval before any printing begins.
Are poly mailers recyclable?
Yes. LDPE poly mailers can be recycled at most grocery store plastic bag drop-offs (check locally).
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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