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How to Design and Personalize Your Mailer Bags - Package N' Go

How to Design and Personalize Your Mailer Bags

mailer bags

In today’s market, distinct mailer bag designs are a hallmark of each brand. These bags not only attract attention but also present your brand in the best light, whether you’re shipping products or building awareness.


Your packaging is the first tangible interaction customers have with their orders. This is where customized mailer bags shine, setting your brand apart and creating a memorable experience.

At Package N’ Go, we will be guiding you through the intricacies of designing and customizing mailer bags to align seamlessly with your brand ethos.

There are a few variables to take into account while selecting the ideal material for a mailer bag. There are several options, including poly mailer bags, bubble mailer bags, foam padded mailer bags, etc.


For the bubble mailer itself, there are different categories as well, including kraft bubble mailers, co-extruded bubble mailers, pearlescent bubble mailers, and metallic bubble mailers. Each one has its own features.

Types Materials Features
Regular poly mailer Co-extruded film Suitable for most applications Cost-effective
Biodegradable poly mailer Biodegradable poly film Biodegradable materials Eco-friendly
Kraft bubble mailer Kraft paper Bubble wrap Shock resistance Writable Cost-effective
Co-extruded bubble mailer Co-extruded film Bubble wrap Shock resistance Cost-effective
Pearlescent bubble mailer Pearlescent film Bubble wrap Shock resistance Visual appealing
Metallic bubble mailer Metallic film Bubble wrap Shock resistance Luxurious appearance
Foam padded mailer Kraft paper Water-based adhesive cushioning dots Shock resistance Biodegradable materials Eco-friendly

For shipping ordinary products, an ordinary poly mailer would be good enough. While for shipping fragile stuff, a bubble mailer or a foam padded mailer would perform better as they are designed with cushioning that can help prevent crushing and collision during transportation.

You also need to take environmental impact into consideration. Opting for a recycled, recyclable or biodegradable material can help reduce your carbon footprint. Besides, good environmental awareness plays a vital role in improving brand image as well. It signals to customers that you care about sustainability.

Success depends on choosing the best material for your particular needs. When making a decision, take into account elements like price, usability, weight, size, and environmental impact. You may choose a mailer bag that satisfies your needs and matches your budget by taking the time to do your research and consider the advantages and disadvantages of each choice.

Classified by structure, mailer bags have different types. If you don’t have a special requirement, the regular self-sealing poly mailer is a good option.

But if you want your mailer bag to be more creative, there are a lot of options you can consider.

A poly mailer with handle, as the name suggests, has a die-cut handle on the top of the bag, which makes it easier to carry. The dedicated design makes a higher grade first impression on customers. With practically NO additional charges, this unique capability has helped make shipping even more convenient.

Besides, handle poly mailers can better display the look of the mailer bag, as people don’t have to tuck them under their arms so that the marketing information can be better displayed.

If you want your products to be seen, the clear-view poly mailers, with a co-extruded film on one side and a transparent PE film on the other side, can perfectly meet your need. Your customers will be able to view everything they’ve ordered from your company by using clear-view poly mailers. These mailers also give your deliveries a professional appearance and feel, making them perfect for companies who place a high value on presentation.

The wicket poly mailer is a standout choice for companies with a large volume of shipments that wish to simplify their packaging procedure. Compared to traditional mailer bags, packing large bulk orders with wicket poly mailers is much easier and more efficient with the handy tear-down function of the incorporated wicket on the top. Businesses will be more confident to keep things moving smoothly by having sufficient of these mailers on hand.

A poly mailer with double self-sealing strips is also called a returnable poly mailer. It has a distinctive design that makes it easily used for a second time, effectively reducing plastic waste. After being opened at the easy open line between the two adhesive strips, the bag still can be used for future shipment or for returning the product because there is an adhesive strip that remained unused. Simply put, it appears to be a brand-new mailer bag.

A brand’s ability to be identified as an environmentally friendly company can be greatly aided by this minor modification in design. Making use of eco-friendly resources and design decisions is a way to demonstrate commitment to the environment and win over prospective customers.

A poly mailer with a tear strip is a creative packaging idea that makes the tedious chore of opening items easier. This poly mailer, sometimes referred to as a tear strip poly mailer or a tear off poly mailer, has a perforated tear-off strip that can be opened without the use of any additional tools.

This packaging solution emphasizes sustainability in addition to convenience. We may conserve resources and cut waste by employing the poly mailer once again as the bag won’t be destroyed when it’s opened. Promoting a green lifestyle involves making every attempt to lessen our negative environmental effects. As a result, this product helps us live easier lives while simultaneously promoting the global objective of environmental preservation.

The gusseted poly mailer, which comes with bottom and side gusset options, is made to increase loading capacity while offering the best protection for your goods. For companies looking for a dependable and effective means to transport their products, its distinctive shape makes it possible for bulkier objects, such as books or gift boxes, to be easily inserted. Besides that, the robust, waterproof material guarantees that the goods reach their destination in immaculate condition, and the option of customization promotes brand awareness and credibility.

Choosing the right style and concept for a poly mailer involves considering your brand identity, target audience, product type, and shipping needs. Here are some suggestions and examples for different product categories:

mailer bags



Style: Elegant and sophisticated.

Concepts: Soft pastel colors, floral patterns, minimalist design with metallic accents.




Style: Trendy and fashion-forward.

Concepts: Bold typography, monochrome designs, patterns that reflect the current fashion trends.




Style: Playful and fun.

Concepts: Bright colors, cartoon characters, interactive elements like puzzles or games.




Style: Modern and sleek.

Concepts: Geometric shapes, tech-inspired patterns, metallic accents.


Eco-Friendly Products


Style: Sustainable and natural.

Concepts: Earthy tones, recycled paper textures, eco-friendly symbols.


Home Decor


Style: Chic and stylish.

Concepts: Abstract patterns, minimalistic designs, elegant color palettes.


Fitness Equipment

Style: Energetic and motivational.

Concepts: Dynamic shapes, bold colors, motivational quotes.


Books or Stationery


Style: Intellectual and organized.

Concepts: Classic book patterns, vintage elements, clean lines.


Pet Supplies


Style: Friendly and pet-centric.

Concepts: Paw prints, pet illustrations, vibrant colors.



There are many excellent software programs that are available for designing mailer bags. Preferred formats for design artwork are typically high-resolution files like AI or PDF.




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


Color mode


For printing, opt for CMYK color mode as it’s best suited for four-color process printing. Avoid using RGB color mode as it might lead to inaccurate colors in the printed version.




To prevent font substitution issues, either convert all text to outlines or provide the used fonts. This guarantees that the text appears exactly as intended in the final print.


Graphic elements


When including graphic elements such as logos, images, or icons, ensure they’re of high quality and correctly positioned. It’s important to provide links to these elements. Remember not to use copyrighted images without proper authorization.

Designers of mailer bags should be aware that it is advised against placing designs all the way to the left and right sides due to the possibility of cutting machine deviations. Since mailer bags are often cut continually, there’s a chance that patterns assigned to one side may end up on the next mailer bag’s side – effectively ruining the overall look of both mailers. To keep mailers looking their best, mailer bag designers need to pay attention to how far elements extend in order to avoid this issue entirely.

But, if you absolutely want a full page printing with the design extending to the sides of the bag, or if you are asked not to adjust the design in any way. You can also solve the problem with Package N’ Go. Our professional design and production team will try to zoom out the design file at a certain percentage and add a margin space with similar color so that the machine’s cutting head has a small amount of flexibility so that we can prevent patterns from shifting to the next bag.

It’s also suggested to avoid laying patterns at the bottom edges of the front and back sides of mailer bags. This is because small changes in the machine’s operation during folding could cause patterns to move just a little bit. As a result, patterns that were originally meant for the front side may end up at the back side instead, or the other way around. So, designers must always be mindful of these potential alterations and take the necessary safety steps while constructing mailer bags.

Of course, if you don’t have other choices, the team at Package N’ Go also has strategies that can assist you in this circumstance. With crucial information aimed at conveying to the clients, the front side of the mailer is typically more significant than the rear side. What we can do is ask our engineers to adjust the machine so that the design on the front side can slightly overlap the design on the back side without the reverse happening.

But of course, before any adjustments are made, we endeavor to ensure our customers understand and agree with the changes.

Mailer bags are typically printed using gravure, which requires overprinting, and it has very strict machine requirements. We advise using no more than four colors in the design. If too many colors are applied in the design, or the equipment used does not meet high standards, the issue of inaccurate overprinting or inferior overprinting is likely to arise.

One of the main causes of inaccurate overprinting is a film issue, such as uneven film winding, unequal film thickness, ruffles, or the film is too slippery or smooth. Also there could be problem of the equipment, for example, the tension setting of the printing machine does not match or the tension system is out of order.

Inferior overprinting can be caused by a number of factors, such as malfunctioning equipment components, improper tension control or differences in the thickness and texture of raw materials. Furthermore, due to the expansive/contractive material qualities, little text or lines in multicolor printing designs are more likely to cause issues when printed. As a result, choosing spot color or monochrome is likely a better option for these aspects.

mailer bags

It’s important to keep in mind while designing mailer bags that the adhesive area better not have any decorations. To maintain the best functionality and financial efficiency, this area is suggested  to be left bare. Not only does it save the printing cost, it also will avoid the ink from degrading the adhesion quality.


The size of the closed flap is suggested to be around 1 cm bigger than the area that needs to be sealed so as to avoid the design to be covered by the flap after sealing. Mailer bag designers can help enhance mailer bag success by ensuring that expensive mail items are adequately secured with strong adhesion by making sure to keep that area clean from patterns or designs.

For special mailer bags like bubble mailers, it is advised against using color or patterns on the left and right sides of the crimped edges, the width of which are usually 1cm – 1.5cm. This is because the sides of the bubble bags are pressed together under high temperatures, which may cause color loss or show white patches. Make sure that there are no patterns or colors on either side of the mailer’s crimping edge to safeguard your mailer bag design from these unwelcome incidents.

mailer bags

Please be aware that finished bags frequently have an eye mark or a locator mark—a little black line strip—in the center or corner. This component, which is visible on the mailer bag, aids automatic cutting machines in determining the precise places that need to be trimmed. Hence, even though this element may not have been a part of your mailer bag design, it is crucial to the creation of mailer bags.

You are eager to create your own distinctive mailer bag after learning so much about mailer bag design? The design of the mailer bag contains a lot more intricate and specialized knowledge. In the future, Package N’ Go will continue to blog about shapes, sizes, printing, and other design-related topics. Package N’ Go can be your assistant if you don’t have the time to do your own design and need assistance. For your product and brand, our skilled design team will produce the ideal package. Contact us right away!

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