Padded Mailers

Always the inside. Padding thickness varies between constructions, so two mailers with the same outer size can have noticeably different usable interiors.

Only if boxes are arriving crushed. If they arrive intact with damaged contents, the product is moving inside and a heavier outer changes nothing. A fitted insert solves that case, usually at lower cost.

Yes, and for padded mailers we prefer to specify both together. A cavity that holds the contents still often lets us drop a grade on the outer, so the pair can cost less than an over-specified box alone.

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 padded mailers carry.

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.

Through store drop-off in many areas rather than curbside 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.

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.

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.

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.

Ordered online, padded mailers start from $0.30 per unit on our standard build, with free shipping to the US, UK, Canada and Australia. For special sizes, materials or large runs we quote, and for this format the biggest levers are quantity, print route, board grade and how many finishing passes are involved. An insert often lowers the total rather than raising it, because holding the contents still lets us drop a grade on the outer.

Yes. We can send a plain unprinted sample so you can check the fit and structure, or a printed prototype for color and finish. Sample costs are normally credited against the production order. On padded 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.

Send the current specification or a physical sample and we will quote to match it rather than proposing an alternative you would then have to re-approve internally. A physical sample tells us more than a specification sheet — board caliper and coating are usually described loosely and measured exactly.