Long Poly Mailers for Blueprints, Plans & Documents

A long poly mailer is an extra-length plastic shipping envelope made for rolled documents — ours are 45 inches long, made of 4 mil low density polyethylene (LDPE), and close with a peel-and-stick self-seal adhesive strip. The length is what sets them apart from standard poly mailers: a rolled 24" x 36" blueprint is about 37 inches long, which will not fit a normal mailer.

Standard architectural blueprints (24" x 36") rolled fit comfortably in a 9.5" x 45" mailer with room for end caps. If rolled tightly, 30" x 42" plans also fit. For thick multi-sheet plan sets or larger sheets, step up to the 13" x 45" size.

Roll your document, measure the roll's length and diameter, then pick a mailer at least 2 inches longer than the roll and wide enough to lay the roll flat — a flat mailer's width needs to be roughly 1.6 times the roll diameter. In practice, 9.5" x 45" handles single rolled plans up to about a 5" diameter roll, and 13" x 45" handles fatter plan sets and rolled banners.

Yes — poly mailers are accepted by USPS, UPS, and FedEx, and the self-seal closure plus water-resistant film holds up to normal parcel handling. Keep in mind that carriers apply nonstandard-length surcharges to long parcels, so check the current rate rules for a 45-inch package before you quote shipping.

The polyethylene film itself is a moisture barrier, so a sealed poly mailer keeps rain, snow, and damp handling off your documents — but it is water-resistant, not submersible. The adhesive flap and factory seams are the weak points, so for outdoor job-site drops wrap the plans in a poly bag inside the mailer for a second barrier.

Use a poly mailer when you want moisture protection and the lowest shipping weight, and a rigid tube when the plans must not be bent or crushed. Poly mailers are flexible, cost less per unit, weigh almost nothing, and won't let water through; tubes resist crushing but absorb moisture and add dimensional weight. Most architects and contractors ship routine plan sets in poly mailers and reserve tubes for originals, renderings, and artwork.

4 mil polyethylene — our standard — gives good puncture and tear resistance for rolled plans, drawings, and posters going through normal parcel networks. Thinner 2 mil film is fine for a single lightweight print, and for extremely valuable or delicate originals a rigid mailing tube is the safer choice.

Yes. The smooth polyethylene surface accepts permanent marker, ballpoint pen, and adhesive shipping labels. For a professional look and reliable carrier scanning, use a printed thermal or laser shipping label rather than handwriting.

No — the self-seal adhesive is designed for a single use and cannot be reopened without tearing the film. If you need a mailer that goes out and comes back, use a mailing tube with removable end caps, or ship in a reclosable poly bag placed inside the mailer.

Poly mailers are low density polyethylene (LDPE, resin #4), which is recyclable as plastic film but is not accepted in most curbside bins. Take clean, dry mailers to a grocery or retail store film drop-off with your bags and stretch wrap, and peel off paper labels and tape first since they contaminate the stream.

Yes, custom printing is available on volume orders — we print company names, logos, return addresses, and handling instructions directly on the film. Contact us for current minimums, plate charges, lead times, and pricing on your size and print colors.