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Everything You Need to Know About Custom Bubble Mailers - Package N' Go

Everything You Need to Know About Custom Bubble Mailers


Table of Contents

Chapter 1: Understanding bubble mailers


1.1 What is a bubble mailer?


A bubble mailer, also referred to as a bubble envelope, bubble padded mailer, or bubble mailing bag, is a specialized packaging solution designed to safeguard items during transportation. Constructed as a thin yet protective envelope, it features a cushioned interior composed of bubble wrap, which securely cradles the enclosed contents.


1.2 What items can be shipped with bubble mailers?


– Documents

– Photographs

– Small electronic devices

– Jewelry

– Clothing accessories

– Beauty and cosmetic products

– Crafts and handmade items

– Books or magazines

– Small toys or collectibles



1.3 What are the benefits of bubble mailers?


Effortless packaging


The bubble mailer is designed with a peel-and-seal adhesive closure, streamlining the packing process and ensuring a hassle-free opening experience for consumers with minimal exertion needed.


Shock absorption


The layer of bubbles serves as a shield, effectively dampening and diffusing external impacts and vibrations. This aids in mitigating the effects of these forces on the enclosed items.




The bubble mailers combine high-quality craftsmanship with a lightweight design, effectively curtailing the expenses associated with parcel shipments.


Space Saving


Bubble mailers offer a space-efficient remedy, catering to those seeking to optimize their storage capacities. Their slim profile ensures minimal spatial consumption, and their foldable design facilitates convenient stacking.


Pressure distribution



The abundance of bubbles contributes to an even dispersal of pressure, diminishing the concentration of force on specific points.


Resistance to scratches and friction


The exterior layer of the mailer is purposefully engineered to resist scratching and endure friction. It acts as a durable barrier, offering robust shielding against external elements that might otherwise jeopardize the items.


Waterproof and moisture defenses


Bubble mailers acquire exceptional waterproof and moisture-resistant characteristics.




Bubble mailers offer a fantastic avenue to elevate your brand presence and craft lasting impressions for clientele through tailored designs featuring logos or branding elements.


Chapter 2: Eco-friendliness of bubble mailers


2.1 Are bubble mailers reusable?


Yes. Bubble mailers can be reused, making them a cost-effective and eco-friendly packaging choice. The design enhancements, such as double self-sealing strips and convenient tear lines on the mailer bags, facilitate easy opening and resealing for subsequent uses.


Additionally, there are numerous creative uses for repurposing old bubble mailers. They can serve as effective packing materials, provide extra cushioning for delicate objects, serve as unique gift wrapping, and even offer a protective cover for electronics.


2.2 Are bubble mailers recyclable?



Yes. Once a bubble mailer has been utilized multiple times, it can be directed to designated recycling collection centers for proper recycling.


If the mailer is composed entirely of plastic materials, it falls under the category of plastic film and can be recycled alongside items like bread bags and grocery bags. However, it’s crucial to note that bubble mailers should not be included in curbside recycling programs. Instead, they should be taken to drop-off locations that specifically accept plastic film. Before recycling, remember to remove any paper labels attached to the mailer.


Recycling becomes challenging when the outer layer of a bubble mailer is composed of materials other than plastics, primarily due to the typical difficulty in separating these layers for individual recycling.


Chapter 3: The various kinds of bubble mailers


Based on the film materials employed, bubble mailers come in a diverse array of options, encompassing kraft bubble mailers, co-extruded bubble mailers, pearlescent bubble mailers, as well as metallic bubble mailers.


3.1 Co-extruded film bubble mailers



Co-extruded film bubble mailers are crafted using a specialized plastic film generated through a simultaneous extrusion technique that involves multiple layers of molten plastic. This innovative process seamlessly fuses two or more plastic materials into a unified, multi-layered film via a specially designed die. The outcome is a continuous film with discernible strata, formed by melding diverse molten plastic elements.


Beyond their lightweight nature and excellent cushioning attributes, these bubble mailers also exhibit waterproof characteristics, effectively shielding contents from external influences. Whether safeguarding lightweight or bulky items, co-extruded film bubble mailers stand as versatile options that consistently deliver reliable performance.


3.2 Pearlescent bubble mailers



Pearlescent bubble mailers incorporate a specialized film made from a blend of polypropylene resin, calcium carbonate, pearlescent pigment, and additional additives. These constituents are meticulously blended and subsequently stretched in dual directions. The resultant film boasts several distinct qualities: a milky-white appearance, a pearlescent shimmer, robust tensile strength, effective shading capabilities, moderate density, and unwavering stability. It offers notable stiffness, minimal static electricity buildup, a heightened gloss, impressive whiteness, captivating pearlescent hues, and excels in printing applications.


Pearlescent bubble mailers effectively blend durability and visual appeal. Notably lightweight and user-friendly, these mailers establish themselves as a dependable and economically sensible choice, whether for the protection of delicate items or the infusion of an alluring dimension into your packaging presentation.


3.3 Kraft bubble mailers



Kraft bubble mailers are crafted from kraft paper, a robust type of paper created through the chemical pulping of wood pulp, primarily sourced from softwood trees like pine or spruce. Renowned for its strength, kraft paper undergoes production via the kraft process, treating wood chips with chemicals such as sodium hydroxide and sodium sulfide to convert them into fibers. This treatment eliminates lignin, a natural wood polymer that lends rigidity but renders paper susceptible to weakening and yellowing over time.


Following this process, the resulting pulp is pressed and dried to yield kraft paper. Possessing notable tensile strength and resistance to tears, it proves apt for diverse applications necessitating resilient packaging or wrapping materials.


In the realm of shipping and packaging, kraft bubble mailers have swiftly garnered favor due to their remarkable durability and tear resistance. Comprising a sturdy outer layer constructed from kraft paper and an inner layer of protective bubble film, these mailers effectively safeguard enclosed items from potential harm and deterioration.


Beyond their protective role, these envelopes offer practical advantages. Lightweight and flexible, they facilitate easy manipulation and storage. Moreover, their environmentally-friendly composition supports sustainability, as kraft paper is recyclable and reusable. Altogether, kraft bubble mailers provide a dependable and conscientious solution for secure shipping of valuable and delicate goods.


3.4 Metallic bubble mailers



Introducing a distinctive variant of bubble mailers – the metallic bubble mailer. These mailers embody the epitome of luxury presentation and premium quality. Meticulously designed, they serve as an optimal choice for those seeking a touch of opulence.


Crafted with precision, the construction of these bags extends beyond aesthetics. They provide a robust defense, safeguarding valuable items against light, heat, gases, as well as impeding the infiltration of moisture, oxygen, and other potential adversaries.


Primarily, two categories of metallic bubble mailers exist: aluminized bubble mailers and aluminum foil bubble mailers. To swiftly differentiate between the two, key distinctions come to the forefront.


Firstly, aluminum foil film presents a silvery white or silvery gray hue, while aluminized film boasts a silvery yellow or silvery black appearance, characterized by heightened brightness.


Secondly, the tactile experience varies – aluminum foil film exudes a thicker, more rigid, and weightier feel in comparison to the aluminized film, which is notably lighter and softer to the touch.


Lastly, when folded, aluminum foil film retains crease marks, whereas aluminum packaging swiftly regains its original form, leaving no discernible fold imprints.


3.5 Similarities between the co-extruded film and pearlescent film



Indeed, there exist noteworthy visual resemblances between co-extruded film and pearlescent film, which can pose challenges in initial differentiation.


One method to discern between the two is by examining color variations between their inner and outer layers. In co-extruded film, these layers usually exhibit distinct hues, while pearlescent film maintains a uniform color throughout.


Another distinguishing aspect lies in the films’ elasticity. The co-extruded film demonstrates higher elasticity, facilitating flexibility and stretchability, while the pearlescent film is comparatively less elastic and easily removable.


When burned, the co-extruded film often emits an unpleasant odor, while the pearlescent film is virtually odorless or may even exude a faint fragrance.


Co-extruded film can incorporate recycled materials, underscoring its eco-friendliness. In contrast, pearlescent film typically lacks recycled content in its production process.


In summary, assessing factors like color disparity, elasticity, burning odor, and the utilization of recycled materials enables a clear differentiation between co-extruded film and pearlescent film.

3.6 Hard shell bubble mailers and soft shell bubble mailers



The production method employed in crafting bubble mailers significantly influences their appearance and performance, giving rise to two distinct types: hard shell and soft shell bubble mailers. One pivotal technique, referred to as “foaming,” imparts a textured surface to certain mailers, resulting in the creation of hard shell bubble mailers.


The utilization of foaming in bubble mailers brings forth several advantages, notably heightened resistance to shocks and an enhanced visual allure. The foaming procedure engenders a textured exterior, furnishing an additional layer of cushioning that bolsters the safeguarding of the contents within the mailer. However, it’s noteworthy that the production of hard shell bubble mailers generally entails a higher cost compared to their soft shell counterparts.


Yet, not all films are suitable candidates for the production of hard shell bubble mailers. Films such as aluminum foil films and laser films weighing less than 160g, or co-extruded films below 85g, might prove unsuitable for the foaming process. This is due to potential aesthetic concerns and the potential formation of “bubbles within bubbles” when utilizing these films. Additionally, inadequate lamination between film layers and air bubbles could give rise to issues of air leakage.


Chapter 4: Things to consider when choosing the right bubble mailer


In addition to assessing the outer film materials, there are additional factors to take into account when selecting the appropriate bubble mailer.


4.1 Size of the bubble mailer


To begin, accurately measure the length, width, and height of your shipment, taking into account any protruding parts or additional features. Make note of the largest measurement among these dimensions.


To ensure the utmost protection for your item during its journey, it is crucial to incorporate an appropriate safety margin. We recommend adding an extra 1-2 inches (2.5-5cm) to each dimension of the item’s size. This ensures that it comfortably fits within the bubble wrap and receives comprehensive shielding.


In order to assist you in discovering the ideal match for your product, we have curated a selection of five commonly favored dimensions, accompanied by illustrative examples for better contextual understanding.



4.2 Thickness of the bubble mailer


The outer film thickness


Opting for a thicker outer film enhances durability and tear resistance, making it an ideal choice for items requiring robust protection. Conversely, a thinner film offers a lighter alternative, suitable for lightweight objects or applications with weight considerations.


Bubble size and thickness


Air bubble wrap is manufactured using high-pressure polyethylene combined with whitening agents and additional additives, all subjected to temperatures of up to 230 degrees. These transparent and lightweight bubbles offer multiple benefits, including moisture resistance and the capacity to shield enclosed items from jolts or harm during transportation.


Typically, a bubble measures between 6 to 10 mm in diameter and 2 to 3 mm in height. Larger bubbles are more adept at absorbing impacts during handling, enabling extensive shock absorption capabilities.


The thickness of the bubble layer is commonly measured in gram weight, indicating weight per square meter. A higher gram weight signifies a thicker bubble layer, translating to superior cushioning capabilities. Generally, delicate or easily susceptible items benefit from a thicker bubble layer for enhanced safeguarding. Meanwhile, sturdier items might suffice with a thinner bubble layer.



Attaining the right balance between film thickness and bubble layer weight is vital to prevent air leakage in bubble bags. If the film is excessively thick while the bubble layer is too light, the bubbles might not offer adequate support, elevating the risk of air leaks. If you’re uncertain about the selection, the experts at Package N’ Go are available to provide professional guidance.


4.3 Transportation and storage conditions



When considering transportation and storage conditions, it is advisable to opt for a thicker film and bubble layer to elevate safety and protection levels, particularly during extended periods or in challenging environments.


For instances involving long-distance travel or extended storage, the potential for impacts, vibrations, and other hazards that could compromise packaging integrity is heightened. Employing a thicker film and bubble layer offers an added safeguard against these risks.


Chapter 5: How much are bubble mailers?


5.1 Prices of custom bubble mailers


When buying in large quantities from suppliers in the US without specific customization needs, the prices typically begin at $0.5. However, for businesses seeking greater cost savings, international suppliers provide the option of purchasing custom bubble mailers in bulk, starting at a mere $0.1.


5.2 Factors that influence prices



Size: The size of the bubble mailer is a significant factor. Larger mailers generally cost more than smaller ones due to the increased materials required to manufacture them.


Material: With consistent quantities, sizes, patterns, and other variables, the pricing hierarchy among the four bubble mailer materials is as follows: metallic bubble mailers command the highest price, trailed by pearlescent bubble mailers and co-extruded bubble mailers. The most economical option is the kraft bubble mailer.


Quantity: Buying in bulk usually results in lower per-unit costs.


Thickness: The thickness of the bubble mailer can affect the price. Thicker outer film and bubble padding may be priced higher.


Customization: Custom-printed bubble mailers with your logo or design can lead to higher costs compared to standard, plain mailers.


Chapter 6: Designing bubble mailers


6.1 What design file should be prepared?


When designing a bubble mailer, you unlock the chance to infuse it with your brand identity, logo, and distinct design elements. Take the following aspects into consideration when preparing your design files.


File format


Optimal file formats for design artwork are typically those that boast high resolution, such as AI or PDF.




Ensure a resolution of at least 300 DPI (dots per inch) to guarantee a sharp and clear print.


Color mode


Use the CMYK color mode for printing since it has been optimized for four-color process printing. The RGB color mode should not be used as the colors might not print as intended.




To avoid any potential problems with font replacement, convert all text into outlines or give the typefaces used in the design. This ensures that the text will print exactly as intended in the finished product.


Graphic elements


Provide the required links and make sure that all graphic components (logos, photos, and icons) are of the highest caliber and precisely positioned inside the design. Be careful not to use copyrighted photos without the required permission.


6.2 Tips for designing custom bubble mailers



Keep the adhesive area free from printing


Make sure to avoid printing on the adhesive area of the mailer bag. This not only saves on printing costs but also ensures that the adhesive remains effective without being affected by ink. Remember to allocate an additional centimeter when determining the size of the closed flap. This prevents your design from being hidden when the flap is tightly sealed.


Avoid printing on the left and right edges


It’s recommended not to place graphics right at the left and right edges of the mailer bag due to potential variations in cutting machines. Continuous cutting of mailer bags could lead to designs from one side appearing on the next bag. Additionally, keep in mind that bubble mailers often have edges measuring between 1 and 1.5 cm wide. High temperatures used during sealing might cause color loss or white areas. To prevent these issues, ensure that there are no patterns or colors along the mailer’s crimping edge.


Designs should not extend to the bottom edges of the front and rear sides


Avoid positioning designs at the bottom edges of the front and rear sides of mailer bags. Minor adjustments in the folding process could result in slight shifts in patterns. Consequently, intended front-side designs might end up on the back, or vice versa. Designers should remain mindful of these potential changes and take necessary precautions while creating mailer bag designs.


Consider the Eye Mark



Please note that finished mailer bags often feature a small black line known as an eye mark or locator mark, usually positioned in the center or corner. This mark assists automatic cutting machines in identifying precise trimming areas. While it might not be part of your initial mailer bag design, this element is crucial for the bag’s production process.


Chapter 7: How are bubble mailers made?


The manufacturing process for various types of bubble mailers is comparable. Let’s delve into the procedure using the co-extruded film bubble mailer as an illustrative example.


7.1 Film blowing


The outer layer of the bubble mailer is created through a process known as film blowing. This plastic processing technique involves melting plastic particles and then extruding them into a tubular form. The tubular film is then inflated to achieve the desired thickness using high-pressure air. Once cooled, the film solidifies and reaches its final state.


7.2 Printing


A specialized gravure press is employed for the printing phase to guarantee exceptional quality outcomes. This procedure entails transferring the design onto a copper plate through gravure printing, ensuring accurate ink deposition in specified regions. Subsequently, the inked plate is pressed onto the film, culminating in the finalization of the printing process.


7.3 Bubble wrap production


To begin the process, polyethylene plastic pellets used in creating bubble wrap are introduced into the melting chamber of the extrusion machine. Subject to elevated temperatures and pressures, these plastic granules undergo a transformation into molten plastic. This molten material is then directed through the die head onto a porous roller designed specifically for bubble film. Through drawing, conditioning, cooling, and shaping, the material takes on its definitive form as the inner layer of the bubble film. Concurrently, an additional layer of film is extruded and overlaid with bubbles, composing the outer layer of the bubble film.


7.4 Lamination of the film and bubble wrap


During this phase, the pre-prepared co-extruded film is bonded with the bubble film through lamination. Subsequently, the composite material is folded and readied for the bag manufacturing process.


7.5 Deflation and heat seal


Afterward, the encapsulated air bubbles get punctured and deflated at the junction of each pair of bubble bags, employing specially designed needles on the production line. Once the deflation process is finished, heat seal technology is utilized to securely seal the bubble bags, effectively joining both sides of the bags together.


7.6 Bag cutting and bag making


Following compounding with the self-sealing strip, the material proceeds to the bag cutting and bag making stages, culminating in the creation of a finalized bubble bag product.


7.7 Turnaround


The time it takes to process bubble mailer orders can vary due to several factors. Generally, a longer production period is required for larger quantities and more complex designs or techniques.


For example, if a factory is manufacturing 50,000 standard bubble mailers with no customizations, they usually have the necessary materials on hand, allowing them to complete production in about 7 days. However, if the same quantity of custom-sized bubble mailers with 4-color printing is being produced, the factory must create printing plates and prepare materials, resulting in a longer production time of approximately 15 days.


Chapter 8: How to do the quality inspection for bubble mailers?


During and after the production process, rigorous quality control measures are seamlessly integrated into each stage. The significance of quality inspections for bubble mailers cannot be overstated, particularly in safeguarding the integrity of products throughout transit.


8.2 How many samples will be inspected?


To maintain strict adherence to quality standards, we employ the AQL (Acceptable Quality Limit) inspection method. This involves randomly selecting samples from each batch and comparing them to set acceptance criteria. The number of samples varies based on order quantity and required inspection level.


The AQL inspection consists of two parts: special and general inspection. Standard criteria are often used: CRITICAL DEFECT=0, MAJOR DEFECT=2.5, and MINOR DEFECT=4.0. A minor defect has minimal impact, while a major one renders the product unfit. Critical defects can be hazardous.


Special inspection, following S-4 standards, focuses on functionality. Any critical defects in one bag lead to batch rejection. It covers issues like severe stains, hazardous items, and poor sealing.


For general inspection, we often use level II criteria. For example, with an order of 8000 (word code L) and a sample size of 200, if major defects don’t exceed 10 and minor defects don’t surpass 14, the batch is acceptable.


Using AQL, we ensure every poly mailer batch meets high standards, delivering quality that matches client expectations.



8.3 Quality inspection criteria




Inaccuracies of both the length and width dimensions need to maintain a strict tolerance of 3mm.


The thickness of the outer film


Thickness verification is conducted using a specialized micrometer. For example, a narrow margin of +/- 0.4cmm is allowed for a 6cmm thick outer film.


Film color


The evaluation of film color relies on advanced equipment to meet stringent color expectations.


Ink saturation


Consistent and even ink coverage is essential, striking the right balance between dullness and brightness. This level of precision ensures a tidy appearance meeting professional benchmarks.


Ink adhesion


We adopt a two-step method for assessing ink adhesion. Tape pasting quantifies ink removal and adhesion, while repetitive surface rubbing gauges the efficacy of ink adhesion.


Film stretching force


Comprehensive tensile strength testing of the outer film is carried out in both vertical and horizontal orientations.


Saturation of the air bubbles


Assessing the saturation level of the air bubbles becomes a crucial step in the quality control process, playing a pivotal role in establishing optimal shock resistance capabilities.


Lamination firmness


Thorough testing is conducted to evaluate the firmness of the lamination between the outer film and bubble wrap. This comprehensive assessment guarantees the materials’ robustness.


Gram weight of the bubble mailer


Samples are collected using a gram sampler to evaluate their adherence to the standard gram weight.


Edge sealing firmness


The effectiveness of edge sealing significantly influences strength, durability, and compliance with safety standards.


Adhesive sealer firmness


The violence test is conducted to assess the firmness of the adhesive sealer. This test involves subjecting the seal to varying levels of force to evaluate and confirm its effectiveness.



8.4 Who does the quality inspection?


Supplier quality inspection


At Package N’ Go, we boast an exceptional team of proficient experts and cutting-edge facilities dedicated to ensuring the quality of our products. To provide our clients with absolute assurance, we furnish them with exhaustive inspection reports that underscore our commitment to their satisfaction.


Third-party quality inspection


For those who seek an additional layer of certainty, we extend the option of third-party inspections. We maintain a close collaboration with esteemed inspection entities to ascertain the thoroughness and credibility of their evaluations.


Some of the distinguished inspection bodies we partner with include:


SGS: A globally-renowned establishment boasting a presence in excess of 90 branches and 200 laboratories worldwide.


TUV Rheinland: As a leading global authority in product inspection and certification, TUV Rheinland has a prestigious 130-year legacy, operating across 30+ countries.


Chapter 9: Conclusion



In this comprehensive guide, we’ve delved deeply into every aspect of custom bubble mailers. As a reputable American company with a global reach, Package N’ Go operates with a cutting-edge supply chain centered in China. With over two decades of unwavering commitment to delivering tailor-made packaging solutions, we have evolved into a distinguished leader in the field.


Our pride lies in offering an extensive array of custom packaging solutions, including custom bubble mailers, custom boxes, and custom poly mailers. Whether you’re a burgeoning startup or a well-established enterprise, Package N’ Go stands ready to fulfill your unique requirements. Setting the industry benchmark, our remarkably low minimum order quantities (MOQ) encompass 10,000 mailer bags and 500 boxes.


Seize the opportunity today to tap into Package N’ Go’s exceptional packaging offerings. Contact us without delay and embark on a journey with us toward exceptional packaging solutions.

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