Poly Mailers with Logo: Brand Your Shipments for Less
Why Branded Poly Mailers Are a Game-Changer
Poly mailers are the most cost-effective way to ship soft goods, apparel, and lightweight products. Adding your logo transforms them from a generic shipping envelope into a brand experience that customers remember.
The ROI is compelling: branded poly mailers cost just $0.15–$0.30 more than generic white mailers, but they drive measurable increases in customer loyalty, social sharing, and repeat purchases. Studies show that 52% of consumers are more likely to reorder from a brand that delivers products in branded packaging (Shorr Packaging, 2025).
Custom Poly Mailer Materials
Standard Co-Extruded LDPE
The industry workhorse. Two-layer film: opaque outer layer (white, grey, or custom color) bonded to a dark inner layer that blocks contents from view. Available in 2.5 mil (lightweight) to 4 mil (heavy-duty). Cost: $0.08–$0.40/mailer.
Recycled LDPE (50–100% PCR)
Made from post-consumer recycled plastic. Same strength and features as virgin LDPE with a sustainability story. Grey or speckled appearance is common. Cost: $0.12–$0.50/mailer. Eco-friendly packaging options.
Compostable (PBAT/PLA Blend)
Plant-based poly mailers that decompose in commercial composting facilities within 90 days. ASTM D6400 certified. Slightly less tear-resistant than LDPE but fully functional for most products. Cost: $0.20–$0.60/mailer.
Poly Mailer Sizes for Clothing
| Size | Dimensions | Best For |
|---|---|---|
| Extra Small | 6" x 9" | Jewelry, accessories, socks |
| Small | 9" x 12" | T-shirts (folded), underwear, scarves |
| Medium | 10" x 13" | T-shirts, blouses, leggings |
| Large | 12" x 15.5" | Jeans, sweaters, dresses |
| Extra Large | 14.5" x 19" | Jackets, coats, multiple items |
| Jumbo | 19" x 24" | Bulk orders, large garments |
Printing Options for Logo Poly Mailers
Flexographic Printing (2,500+ Units)
1–4 color printing using rubber plates. Best value for simple logos and brand patterns. Cost: $0.12–$0.25/mailer at 5,000 units. Plate fees: $150–$250 per color.
Digital Printing (500+ Units)
Full-color photographic printing with no plates. Perfect for complex logos, Instagram-worthy designs, and seasonal variations. Cost: $0.25–$0.50/mailer at 500 units.
Custom Poly Mailer Features
- Self-Seal Adhesive Strip: Peel-and-stick closure for tamper-evident sealing (standard on all)
- Dual-Peel Return Strip: Second adhesive strip for easy customer returns (adds $0.02/mailer)
- Bubble Lining: Integrated bubble wrap for moderate product protection (adds $0.05–$0.15)
- Expansion Gusset: Side gussets for thicker items like shoes and books (adds $0.03)
- Clear Outer Pocket: For packing slips and shipping labels (adds $0.02)
Pricing Guide
| Quantity | 1-Color Logo | Full-Color | Eco/Compostable |
|---|---|---|---|
| 500 | N/A | $0.25–$0.50 | $0.35–$0.60 |
| 1,000 | N/A | $0.20–$0.40 | $0.28–$0.50 |
| 2,500 | $0.12–$0.25 | $0.18–$0.35 | $0.25–$0.45 |
| 5,000 | $0.08–$0.18 | $0.15–$0.28 | $0.20–$0.40 |
| 10,000+ | $0.06–$0.12 | $0.10–$0.22 | $0.15–$0.30 |
Poly Mailers vs. Mailer Boxes: Which Should You Choose?
Use poly mailers for soft, non-fragile items like clothing, textiles, and accessories. Use mailer boxes for fragile items, products that need structure, and premium unboxing experiences. Poly mailers cost 60–80% less than boxes and weigh 70% less — dramatically reducing DIM weight shipping costs.
Get a free quote for custom poly mailers with your logo →
Related Guides
- Custom Mailer Boxes with Logo Guide
- Custom Labels for Small Business Guide
- Custom Cosmetic Packaging Boxes Guide
📦 Ready to Order Custom Poly Mailers?
From $0.08/mailer. Eco-friendly and compostable options. 500 MOQ.