Custom Poly Mailer Pricing: Cost Per Unit Breakdown (2026)
How Much Do Custom Poly Mailers Cost in 2026?
Custom poly mailers range from $0.08 to $0.80 per unit depending on size, film thickness, printing, and features. Plain white mailers start at $0.08/unit, while premium branded mailers with dual-peel return strips and recycled content run $0.30–$0.80/unit.
Quick answer: A standard 10×13" poly mailer (2.5 mil) with full-color digital printing and self-seal closure costs approximately $0.18–$0.25/unit at 2,500 units.
Price Per Unit by Size
Standard 2.5 mil white poly mailer with full-color printing:
| Size | Common Use | Price at 500 | Price at 2,500 | Price at 10,000+ |
|---|---|---|---|---|
| 6×9" | Jewelry, accessories | $0.18–$0.28 | $0.10–$0.16 | $0.08–$0.12 |
| 7.5×10.5" | T-shirts, small items | $0.20–$0.32 | $0.12–$0.20 | $0.09–$0.14 |
| 10×13" | Most clothing | $0.25–$0.38 | $0.15–$0.25 | $0.10–$0.18 |
| 12×15.5" | Jeans, hoodies | $0.30–$0.45 | $0.18–$0.30 | $0.12–$0.22 |
| 14.5×19" | Jackets, multi-item | $0.38–$0.55 | $0.22–$0.38 | $0.15–$0.28 |
| 19×24" | Bedding, bulky items | $0.50–$0.75 | $0.30–$0.50 | $0.20–$0.38 |
Price by Thickness
Using 10×13" mailer at 2,500 units:
| Thickness | Feel | Puncture Resistance | Cost/Unit | Best For |
|---|---|---|---|---|
| 2.0 mil | Thin, budget | Basic | $0.12–$0.18 | Ultra-lightweight items |
| 2.5 mil | Standard | Good | $0.15–$0.25 | Most e-commerce (default) |
| 3.0 mil | Premium | Very good | $0.20–$0.32 | Items with edges, premium brands |
| 4.0 mil | Heavy-duty | Excellent | $0.28–$0.42 | Heavy items, luxury feel |
Feature Add-Ons
| Feature | Add-On Cost | Why Use It |
|---|---|---|
| Self-seal strip | Included | Standard tamper-evident closure |
| Dual-peel return strip | +$0.02–$0.05 | Second adhesive for easy customer returns |
| Bubble liner | +$0.10–$0.25 | Built-in cushioning for moderate protection |
| Perforation tear strip | +$0.01–$0.03 | Clean opening without scissors |
| Suffocation warning | +$0.00 | Required for bags over 5" opening |
| Document pouch | +$0.03–$0.08 | External pocket for packing slip |
Material Options
| Material | Composition | Cost vs Standard | Best For |
|---|---|---|---|
| Virgin LDPE | 100% new plastic | Baseline | Standard shipping |
| 50% PCR | 50% post-consumer recycled | +10% | Eco-conscious brands |
| 100% PCR | 100% recycled plastic | +15–20% | Sustainability leaders |
| Compostable | PBAT/PLA bioplastic | +40–60% | Zero-waste brands |
Poly Mailer vs Box: Shipping Cost Savings
| Package | Weight | DIM Weight | Actual Ship Cost (USPS) |
|---|---|---|---|
| 10×13" poly mailer | 1.5 oz | 0 (flat) | $3.50–$5.00 |
| 10×8×4" box | 8 oz | 320 cu in | $6.50–$9.00 |
| Savings | -6.5 oz | -320 cu in | $3.00–$4.00 per shipment |
At 1,000 shipments/month, switching from boxes to poly mailers saves $3,000–$4,000/month in shipping alone.
Ready to price your custom poly mailers? Get a free quote or browse our collection.
Order custom mailer boxes. Custom Mailer Boxes → — branded E-flute corrugated with interior printing. From $0.50/unit, 500 MOQ. Browse all mailer boxes →