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9x12 Poly Mailers
Custom 9x12 Poly Mailers produced to your size and substrate, with printing and finishing handled in one run.
- Minimum order
- 100 units
- Production
- 3–5 business days
- Construction
- poly mailer
- Delivery
- US, UK, Canada, Australia
No obligation
Start a quote
Name, email, phone and what you are packing and how it ships. Attach artwork if you have it. We reply with a specification and a written price, usually within one business day.
What 9x12 poly mailers have to cope with
9x12 Poly Mailers hold a single folded garment — a t-shirt, a pair of leggings, a light knit. That is the starting point for the specification, because this size is right for one garment. If a meaningful share of orders is two items, a second larger size costs less than the failures.
In service they are used for apparel fulfilment where single-garment orders are the majority of despatch.
Where 9x12 poly mailers are actually used
9x12 Poly Mailers are specified for apparel fulfilment where single-garment orders are the majority of despatch. This size is right for one garment. If a meaningful share of orders is two items, a second larger size costs less than the failures.
- Apparel fulfilment where single-garment orders are the majority of despatch
- Apparel and soft goods shipping
- Lightweight e-commerce orders
- Returns programmes
The substrate for 9x12 poly mailers
2.5 mil co-extruded polyethylene is standard at this size; 3 mil where garments have zips or hardware that could catch.
The options we would consider for this format are below; this size is right for one garment. If a meaningful share of orders is two items, a second larger size costs less than the failures.
- 2.5 mil coextruded LDPE
- 3 mil coextruded LDPE
- 100% recycled LDPE
- Compostable PBAT/PLA film
How 9x12 poly mailers fail, and what prevents it
Two garments in a 9 × 12 strains the seal, and the failure happens in the carrier network rather than at the packing bench.
This size is right for one garment. If a meaningful share of orders is two items, a second larger size costs less than the failures.
Printing 9x12 poly mailers
A small print area by mailer standards. A logo and a return address read better here than a full-coverage design.
Flexography, Digital film printing are all available for this format. Run length usually decides which is cheapest: digital removes the plate cost on short quantities, offset and flexo overtake it at volume.
Sizing 9x12 poly mailers
9 × 12 in is the single most common apparel size, comfortable for one folded garment and tight for two.
Send the contents rather than a box size. Operations standardise on 9 × 12 for everything and then force two-item orders into it rather than stepping up a size.
What moves the price
Four things drive a quote more than anything else: the quantity, the print route, the board grade and the number of finishing passes. Dimensions matter too, but usually through how efficiently the shape nests on the press sheet.
Prices start from $0.30 per piece for large-volume orders. If a cheaper route exists we say so at quoting rather than after the invoice.
Getting them to you, and onward
Poly mailers are light and take almost no freight volume, which usually lowers your outbound postage band.
Delivery windows are confirmed in writing when your order moves into production, and we flag any risk to the date before you approve rather than after.
Preparing artwork
Flexo on film holds solid colours cleanly. Keep reversed-out type above 8pt and avoid fine screens under 15%.
Supply a print-ready PDF or vector file with fonts outlined and images at 300 dpi. Our prepress team checks every file before a proof is issued. The check that catches most files is type sitting too close to a crease, which is easier to move at layout than at proof.
How an order runs
Start with dimensions and quantity. If you already run something similar, a physical sample tells us more in a minute than a specification does in a page.
We send a dieline sized to your product, check your artwork and issue a proof. For shipping formats we will also flag it if the pack looks a size larger than it needs to be.
Proving it before the run
Ask for an unprinted sample if the question is fit, or a printed prototype if the question is colour. They answer different things.
Sample costs are normally credited against the production order.
Reference
9x12 Poly Mailers at a specification level
| Product | 9x12 Poly Mailers |
|---|---|
| Category | Custom Mailers |
| Construction | Poly mailer |
| Film gauge | 2.5 mil – 3 mil coextruded |
| Closure | Permanent self-seal adhesive strip |
| Opacity | Opaque, contents not visible |
| Materials | 2.5 mil coextruded LDPE, 3 mil coextruded LDPE, 100% recycled LDPE, Compostable PBAT/PLA film |
| Printing | Flexography, Digital film printing |
| Finishes | Matte film, Gloss film, Metallic film |
| Minimum order | Minimum order is 100 units on any format, and unit cost falls sharply as the quantity rises. |
| Lead time | 3 to 5 business days after artwork approval |
| Shipping | Across the US, UK, Canada and Australia |
Specification builder
Specify 9x12 Poly Mailers in under a minute
Set what you know, leave the rest. Everything here travels with your request, so nothing gets retyped.
- 100-unit minimum
- 3–5 day production
- Free dieline
- No obligation
9x12 Poly
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In transit
What survives the journey
Cut to the load
9 × 12 in is the single most common apparel size, comfortable for one folded garment and tight for two.
The damage this prevents
Two garments in a 9 × 12 strains the seal, and the failure happens in the carrier network rather than at the packing bench.
Where it is used
Specified for apparel fulfilment where single-garment orders are the majority of despatch.
The detail that decides it
This size is right for one garment. If a meaningful share of orders is two items, a second larger size costs less than the failures.
This format sits in our custom mailers range, alongside 31 other made-to-order formats.
Answers
9x12 Poly Mailers: protection and transit
Specification, minimums and lead times for 9x12 poly mailers.
Will two garments fit in a 9x12 mailer?
It will close but the seal is strained, and that is where failures happen in transit. If two-item orders are a meaningful share of your despatch, a second larger size costs less than the replacements.
How do I reduce dimensional weight?
Measure the product rather than the box currently in use. Most operations we quote are running at least one size too large with void fill compensating, and dropping a band saves on every parcel 9x12 poly mailers carry.
Should the outside be printed?
That is a brand decision, not a cost or protection one. For direct-to-consumer parcels where the customer opens it, print can be worth it. For business deliveries it usually is not.
Are poly formats recyclable?
Through store drop-off in many areas rather than kerbside collection. Mono-material polyethylene is the more recyclable option; mixed-material films generally are not. If recyclability is a stated claim, tell us and we will keep to a mono-material construction.
What happens after I approve the quote?
We issue a dieline template sized to your product, prepress checks your artwork against it, and a proof comes back for sign-off. Nothing runs until you approve that proof, and poly mailers then take 3 to 5 business days.
Can you hold the specification for repeat orders?
Yes. Once a first run is approved we hold the board, structure, dimensions, print method and finishes against your account, so a reorder references the same specification exactly rather than being re-derived. It also means a reorder can be priced against a larger quantity without re-opening the specification.
Do you offer recycled or recyclable options?
Recycled grades are available across most of the substrates we run for poly mailers. Recycled content, kerbside recyclability and certified compostability are three different claims though, so tell us which one you intend to print.
What file format should I send artwork in?
A print-ready PDF or a vector file, with fonts outlined and any raster images at 300 dpi at final size. We supply the dieline to design onto, and prepress checks bleed, safe area and crease clearance before issuing a proof. The dieline we supply carries the crease positions, so keeping type clear of a crease is easier to solve at layout than at proof.
What is the minimum order for 9x12 poly mailers?
A flat 100 units on any format. Most poly mailers in this range are quoted from 100 units upward because unit cost falls sharply above that, but the minimum exists so you can validate a structure first.
How long do 9x12 poly mailers take to produce?
3 to 5 business days after artwork approval, plus freight. Poly mailer runs with applied finishes can take longer because each finish is a separate pass, and we confirm a firm date in writing with the quote.
What do 9x12 poly mailers cost?
Prices start from $0.30 per piece for large-volume orders. For this format the biggest levers are quantity, print route, board grade and how many finishing passes are involved. We quote each element separately so you can see where the money is going. An insert often lowers the total rather than raising it, because holding the contents still lets us drop a grade on the outer.
Can I see a sample first?
Yes. We can send a plain unprinted sample so you can check the fit and structure, or a printed prototype for colour and finish. Sample costs are normally credited against the production order. On 9x12 poly mailers the thing to check is whether the contents still sit tight once the pack is closed, because movement inside is what causes damage rather than the board grade.
Next step
Start on 9x12 Poly Mailers
Send the dimensions, the quantity and how it ships. We reply with a full specification and a written price, usually within one business day.