The Different Types of Tear Open Boxes Available in the Market

Table of Contents

Tear open boxes, alternatively referred to as tear strip boxes or easy open boxes, are the ideal packaging solution for those seeking a quick and effortless access to its contents. These boxes feature a tearable strip or perforated line, avoiding the need for additional tools or equipment.


For businesses in the packaging industry, it is vital to comprehend the different types of tear open boxes available. By doing so, companies can offer custom-made packaging solutions that perfectly fit their clients’ exact requirements. Additionally, in-depth knowledge of tear open boxes empowers businesses to educate their customers on the unique benefits and characteristics of each option, thereby enabling them to make well-informed choices.


Basic types of tear open boxes and their features


In fact, easy tear tape can be incorporated into various packaging products, including cardboard boxes, corrugated boxes, and shipping boxes, among others. Rigid boxes typically do not use easy tear tape because they often have user-friendly opening mechanisms such as flip-top lids, book-style openings, or sliding drawers. However, when confidentiality is required for rigid boxes, easy tear tape can be a great solution.


For traditional boxes, the decision to include easy tear tape depends on factors such as convenience of opening and the specific needs of packaging and transportation. We recommend using easy tear tape for boxes containing daily consumer goods, cosmetics, food, medicine, and similar products where easy opening is essential.


Here are some examples of tear-open box types:


Cardboard zipping obelisk box



The cardboard zipping obelisk box is a tear open box that features a zip-like mechanism for easy opening. The box is typically made of sturdy cardboard material, ensuring durability and product protection. The zip design allows for a smooth and controlled tear, preventing accidental damage to the product or packaging.


Shelf-ready packaging with tear open



Shelf-ready tear open packaging is specifically designed for easy stocking and display on retail shelves. These boxes often include tear open features, enabling store staff to quickly and effortlessly open the packaging and place the products on the shelves. This type of tear open box is typically made from corrugated cardboard, providing both strength and visual appeal.


Tear strip carton box with adhesive tape


This particular type of tear open box boasts a unique feature – a plastic tear stirp or “easy pulling line”. This small but impactful addition makes for an effortless and efficient process for the user. With a gentle pull, the line easily slices through the material, making unpacking a breeze. The end result is a practical and convenient solution that simplifies the process of receiving and opening packages.


Tear-off, zipper top cover carton



The tear-off, zipper top cover carton is a tear open box that features a tear strip along the top cover, allowing consumers to open the packaging by simply pulling the tear strip. The zipper-like design provides a controlled tear, ensuring a clean opening and easy access to the contents. This type of tear open box is commonly used in industries such as snacks, cereals, and other food products.


Tear-open napkin box



Tear-open napkin boxes are specifically designed for easy access to napkins or tissues. These boxes typically have a perforated line or tear strip that allows users to tear open a section of the box to retrieve the napkins. The tear open feature ensures convenience and hygienic dispensing, particularly in restaurants, hotels, and other establishments.


Mailer box with zipper


The mailer box with a zipper is a tear open box designed for shipping and e-commerce purposes. These boxes typically feature a tear strip or perforated line that allows for easy opening upon delivery. The addition of a zipper feature enables the recipient to reseal the box if necessary, providing flexibility and convenience.


Types of tear strips


The tear strips on tear-open boxes come in various types, each designed for specific opening mechanisms or user experiences. Here are two common types of tear strips used on tear-open boxes:


Die-Cut Tear Strip


Die-cut tear strips are precisely engineered, featuring a specialized cut or groove in the packaging material that enables easy tearing along a predefined path. These tear strips are used across a wide range of packaging solutions, including electronics, toys, and household goods boxes. The die-cut design ensures that users can effortlessly follow the intended tear line, making the opening process intuitive and user-friendly. This type of tear strip enhances the overall unboxing experience, ensuring consumers can access the product inside easily.


Pull Tab Tear Strip


Pull tab tear strips feature a small, user-friendly tab or extension typically made from durable PVC material. Users can easily grip and pull this tab to start the tearing process. These tear strips are commonly used on packaging for snacks, beverage cartons, and resealable pouches. The PVC pull tab provides a secure and comfortable grip, allowing consumers to open the packaging without needing additional tools. It ensures quick and convenient access to the contents while preserving the package’s integrity. This tear strip design is especially suitable for products requiring repeated access and resealing, making it a popular choice for resealable packaging solutions.


The specific form and implementation of the easy-tear feature depend on the product’s material, intended use, and user requirements. Manufacturers tailor the most appropriate easy-tear solution considering these factors to ensure users can open the product effortlessly and promptly. Additionally, with ongoing technological advancements, we can anticipate the emergence of more innovative and efficient forms of easy-tear in the future.


Benefits of tear open boxes



Easy opening


One of the significant advantages of tear open boxes is their easy opening feature. With a tear strip or perforated line incorporated into the design, these boxes offer a hassle-free and convenient way to access the contents inside. Gone are the days of struggling with scissors, knives, or other tools to open the packaging.


The tear open feature allows users to simply pull or tear along the designated line, providing quick and effortless access to the products. This not only saves time but also eliminates the risk of accidental damage to the items inside. Whether it’s a consumer trying to open a snack package or a store employee unpacking merchandise, the easy-opening functionality of tear open boxes ensures a seamless and user-friendly experience.


Businesses can enhance customer satisfaction and convenience by opting for tear open boxes, simplifying the opening process and making their products easily accessible to consumers.


Product display


Tear open boxes offer excellent display capabilities, allowing businesses to showcase their products effectively. Once the tear open box is opened, it provides an excellent opportunity to showcase the products inside on store shelves. The tear open feature allows for easy access to the contents, and once opened, the box can be conveniently displayed, catching the attention of potential customers.


Whether it’s food products, consumer electronics, cosmetics, or any other items, the tear open box design ensures that the products are visible and attractively presented. This display functionality not only enhances the overall visual appeal but also encourages customers to explore and make informed purchasing decisions. By placing the opened tear open box on the shelf, businesses can effectively showcase their offerings and create a visually appealing shopping experience for customers.


Anti-theft function


Tear open boxes offer an additional layer of security with their anti-theft features. Once the tear strip is opened, it cannot be recovered or resealed without clear signs of tampering. This feature serves as a deterrent to potential theft or unauthorized access to the contents of the box. In retail settings, tear open boxes help ensure that products remain secure until they are purchased. The irreversible nature of the tear strip provides a visible indication that the package has been opened, making it easier for store staff or customers to identify any attempts at tampering.


This anti-theft functionality not only protects the products but also instills confidence in consumers, assuring them that they are receiving intact and authentic items. By incorporating tear open boxes with anti-theft features, businesses can effectively safeguard their products, maintain brand integrity, and enhance customer trust in their offerings.


Tear open boxes for different industries 



Food packaging


Tear open boxes are vital in the food industry to keep products fresh and accessible. With different types of tear open boxes, snacks, cereals, frozen foods, and perishable items are securely packaged and easy to access. Experience unrivaled convenience and product integrity with tear open food boxes.


Pharmaceuticals and medical supplies


Tear open boxes are crucial components of pharmaceutical and medical supply packaging. They are designed to meet specific requirements that guarantee the safety and security of the enclosed products. Tamper-evident seals and child-resistant closures are frequently included in these boxes to prevent unauthorized access and ensure the contents are protected. Trust in the reliability and protective features of tear open boxes for your medication packaging needs.


In the pharmaceutical industry, tear open boxes must adhere to strict safety and security standards. This includes features such as tamper-evident seals, barcode tracking, and serialization to prevent counterfeit products. Tear open boxes can provide added protection and assurance, ensuring that medications and medical supplies reach consumers in their intended form.


Consumer Electronics


Tear open boxes are the trusted choice for consumer electronic packaging, from smartphones to tablets and other gadgets. These clever boxes ensure your products remain safe and secure during shipping and easily accessible upon arrival. Thanks to intuitive zip-like mechanisms or strategically placed tear strips, unboxing the new electronics has never been easier.


When selecting tear open boxes for consumer electronics, it is important to consider the level of protection provided by the packaging material. The box should be able to withstand shocks and impacts, ensuring the safety of the electronic device inside. Additionally, tear open boxes that allow for easy access to user manuals, cables, and accessories enhance the overall user experience.



Other Usage


Tear open boxes are versatile and can be utilized in various industries. For cosmetics, tear open boxes can provide easy access to makeup products and skincare items, enhancing the overall user experience. In the clothing and fashion industry, tear open boxes can be used for packaging apparel, accessories, or jewelry, allowing customers to open and inspect the products easily.


Snack packaging can benefit from tear open boxes, providing a convenient and hygienic way to access snacks while keeping them fresh. Tear open boxes for jewelry offer an elegant and secure packaging solution, allowing customers to unveil their precious items effortlessly.


In the business essentials sector, tear open boxes can be used for office supplies, providing easy access to pens, notepads, and other items. Tear-open napkin boxes ensure quick and hassle-free access to napkins, making them ideal for restaurants, hotels, and other establishments.


Materials of tear open boxes


Tear open boxes can be made from various materials, depending on the specific requirements of the product and industry. Here are some commonly used materials:


CCNB (Clay Coated News Back)


CCNB is a type of paperboard with a clay coating on one side and a smooth surface on the other. It provides excellent printability, making it suitable for tear open boxes that require vibrant graphics and branding. CCNB is lightweight, cost-effective, and offers moderate durability.


SBS (Solid Bleached Sulfate)


SBS is a high-quality paperboard made from bleached wood pulp. It has a bright white appearance, a smooth surface, and excellent stiffness. SBS tear open boxes are commonly used for premium packaging, where a luxurious and pristine presentation is desired.


Kraft paper


Kraft paper is a durable and eco-friendly material made from unbleached wood pulp. It has a natural brown color and a rough texture. Kraft tear open boxes are often used for packaging products that require strength and protection, such as heavy-duty items or industrial supplies.


White kraft paper


White kraft paper is a bleached version of the highly durable and strong regular kraft paper. Despite its lighter color, it still boasts the same resilience with a refined, cleaner appearance. Tear open boxes made of white kraft paper are ideal for various products such as cosmetics, clothing, and electronics. Perfect for those who desire quality packaging with a touch of sophistication.


Corrugated cardboard


Corrugated cardboard consists of a fluted layer sandwiched between two flat layers. It is known for its exceptional strength and cushioning properties, making it ideal for tear open boxes that require robust protection during transportation and handling. Corrugated tear open boxes are widely used in industries such as e-commerce and shipping.


Premium White


Premium white is a high-quality paperboard that offers a luxurious appearance, similar to SBS. It is smooth, bright white, and provides excellent printability, making it suitable for tear open boxes that require a premium and sophisticated presentation.


Standard White


A standard white paperboard is a cost-effective option for tear open boxes. It provides a clean and simple appearance, making it versatile for various industries and products. Standard white tear open boxes offer a balance between affordability and functionality.


Factors to consider when choosing tear open boxes



Material and durability


Consider the type of product being packaged and the level of protection required. Choose tear open boxes made from materials that offer the necessary strength, durability, and barrier properties to safeguard the contents.


Customization options


Evaluate the customization options available for tear open boxes. This includes the ability to incorporate branding elements, such as logos, colors, and graphics, to enhance visual appeal and brand recognition.


Size and shape


Select tear open boxes that are appropriate for the product’s dimensions and shape. The box should provide a secure fit to prevent movement during transportation while ensuring easy access for the end-user.


Cost and efficiency


Consider the cost-effectiveness and efficiency of tear open boxes. Evaluate factors such as production time, assembly requirements, storage space, and shipping costs to determine the most suitable option for your business.


Emerging trends in tear open box designs


Sustainable tear open boxes


With the mounting environmental concerns, the demand for packaging solutions that prioritize sustainability and utilize eco-friendly materials such as recycled paperboard has surged. In response to this growing need, we proudly offer tear-open boxes specifically designed to facilitate effortless recycling and minimize environmental impact. Make a conscious choice for a more sustainable tomorrow by selecting our eco-friendly packaging solutions.


Consumer demand for environmentally conscious packaging – conscious of their environmental footprint and are actively seeking products packaged in sustainable materials. Tear open boxes that align with these consumer preferences can provide a competitive edge and enhance brand reputation.


Interactive tear open boxes


Incorporating augmented reality or QR codes – Tear open boxes can be designed to incorporate interactive elements such as augmented reality (AR) experiences or QR codes. This allows consumers to engage with the packaging and access additional information, promotions, or multimedia content related to the product or brand.


Enhancing user engagement and brand experience – Interactive tear open boxes offer an opportunity to create memorable and immersive experiences for consumers. By combining technology and innovative design, brands can enhance user engagement, build stronger connections, and differentiate themselves in the market.


Understanding the different types of tear open boxes is essential for businesses in the packaging industry. It enables them to provide tailored packaging solutions to meet specific client needs and educate customers about the benefits and features of different tear open box options.



The tear open box industry continues to evolve, driven by advancements in materials, sustainability initiatives, and consumer preferences. Future tear open box designs are likely to focus on incorporating more eco-friendly materials, interactive elements, and enhanced customization options to deliver a memorable and sustainable packaging experience.


By staying informed about the latest trends and developments in tear open box designs, businesses can position themselves as innovative leaders in the industry and attract customers seeking functional, visually appealing, and eco-friendly packaging solutions.


Get your custom tear open boxes from Package N’ Go


At Package N’ Go, we recognize that the distinction between a good business and a great one lies in meticulous details. We have extensive experience in producing classic tear open boxes, which are characterized by quick production, stable quality, and affordable prices.


In addition to tear open boxes, we provide an extensive selection of packaging solutions, including custom poly mailers, custom mailer boxes, custom bubble mailers, custom shipping boxes, custom rigid boxes, and more. Whatever packaging challenges you may face, we have the ideal solution for you. Partner with us to elevate your business’s packaging standards to new heights. Don’t delay any further. Contact us today and let our experts guide you in elevating your packaging to the next level. 

The Ultimate Guide to Tear Open Box

Table of Contents

Chapter 1: Understanding tear open boxes


1.1 What is a tear open box?



Tear open boxes, also known as tear strip boxes or pull-tab boxes, are a type of packaging designed for easy opening. They feature a tear-off strip or perforated section that allows consumers to open the box without the need for scissors or other tools. This innovative design simplifies the unboxing experience and enhances user convenience.


1.2 What items can be shipped with tear open boxes?


Tear open boxes are versatile and suitable for shipping a wide range of products, including but not limited to:


Snacks and Food Products: Tear open boxes are commonly used for packaging snacks like chips, cookies, and candy. They provide easy access to the contents while maintaining freshness.


Electronics: Smaller electronic devices, such as headphones, chargers, and cables, can be shipped in tear open boxes. The secure closure ensures the safety of fragile items.


Cosmetics and Beauty Products: Makeup kits, skincare products, and perfume sets are often packaged in tear open boxes for a sleek and attractive presentation.


Pharmaceuticals: Medications, supplements, and first-aid kits can be shipped in tear open boxes with tamper-evident features to ensure product integrity.

Toys and Games: Tear open boxes can house toys, puzzles, and board games, making it easy for children and adults to access their entertainment.


Small Appliances: Items like coffee makers, blenders, and kitchen gadgets can be safely shipped in tear open boxes, especially when they require appealing packaging.



Fashion Accessories: Scarves, ties, belts, and small fashion items can be elegantly presented in tear open boxes.


Office Supplies: Stationery sets, notebooks, and pens are often packaged in tear open boxes for both retail and office use.


Personal Care Products: Shampoos, conditioners, and toiletry sets can benefit from the convenience of tear open boxes.


Jewelry: Tear open boxes with special inserts can securely hold and display jewelry items such as rings, necklaces, and bracelets.


Promotional Items: Companies often use tear open boxes for promotional giveaways, containing branded merchandise like T-shirts, mugs, and keychains.


Art Supplies: Paints, brushes, sketchbooks, and other art supplies can be packaged in tear open boxes that showcase the creative contents.


Small Gifts: Tear open boxes are an ideal choice for packaging small gifts for special occasions such as birthdays and holidays.


1.3 Common sizes


Here are some common size options for various items, which you can choose based on your specific needs. If you’re uncertain about the right size for your products, don’t hesitate to contact us for assistance.


9.2×9.2×5 cm: These boxes are perfect for jewelry, cosmetics, or small accessories, adding value to your products.


11.8×14×8 cm: Another option suitable for jewelry, cosmetics, and small accessories, providing a slightly larger dimension for your products.


32×18.9×9 cm and 30.2×23.3×8.8 cm: These medium-sized boxes are highly popular for clothing items such as T-shirts, dresses, blouses, trousers, and light jackets, ensuring an ideal fit.


35×26×10 cm: A larger size option for medium-sized clothing items and other products.


44×33.9×15.9 cm and 42.5×52×18 cm: For larger electronic appliances or heavy clothing items, our spacious tear open boxes offer the perfect match.


Remember, we also offer customization options, allowing you to tailor the size to your specific requirements. Feel free to reach out to us to discuss your unique packaging needs and preferences.



1.4 What are the benefits of tear open boxes?


Tear open boxes offer numerous advantages for both businesses and consumers.


User-Friendly Design: The primary advantage of tear open boxes is their user-friendly design. The tear-off strip or perforated section allows for easy and quick opening without the need for scissors or sharp objects. This simplicity enhances the unboxing experience for consumers.


Convenience: Tear open boxes are incredibly convenient for consumers, as they can access the contents effortlessly. This is particularly valuable in today’s fast-paced world where consumers appreciate time-saving solutions.


Brand Visibility: Tear open boxes provide ample space for branding and visual appeal. Companies can use this space to display their logos, product information, and marketing messages prominently, increasing brand recognition.


Customization: Tear open boxes come in various sizes, materials, shapes, and styles, allowing businesses to customize their packaging to suit their products and brand identity. This flexibility makes it easy to create unique and eye-catching designs.


Sustainability: Many tear open boxes can be produced using eco-friendly materials, contributing to sustainable packaging practices. This is increasingly important as consumers become more environmentally conscious.


Retail Presentation: Tear open boxes are ideal for retail environments because they can be displayed attractively on store shelves. Their visual appeal can help products stand out and attract customers.


E-commerce Ready: Tear open boxes are well-suited for e-commerce packaging. They provide both protection and convenience for products being shipped to customers, enhancing the online shopping experience.


Versatility: Tear open boxes can be used to package a wide range of products, from snacks and cosmetics to electronics and pharmaceuticals. Their versatility makes them a popular choice across various industries.


Unboxing Experience: The tear open box’s unique opening mechanism creates an enjoyable unboxing experience for consumers. This can lead to positive reviews, social media sharing, and increased customer loyalty.


Tamper-Evident Features: Tear open boxes can incorporate tamper-evident seals or closures, ensuring that the product has not been tampered with before reaching the consumer.


Cost-Efficiency: These boxes can often be produced cost-effectively, making them an attractive packaging option for businesses looking to balance quality and budget. The tear open box offers a more convenient feature without significantly increasing the cost of production.



Chapter 2: Types of tear open boxes


2.1 Classified By Materials


Tear-open boxes can be classified based on the materials used to make them. The two common categories are paperboard tear-open boxes and cardboard tear-open boxes.


2.1.1 Paperboard Tear Open Boxes


Paperboard Tear-Open Boxes are a popular choice for packaging a wide range of products that require a balance between protection and affordability. These boxes are typically crafted from a thicker and more rigid type of paperboard material, ensuring they maintain their shape and provide adequate safeguarding for their contents. The selection of the appropriate type of paperboard depends on factors such as aesthetics, functionality, and product requirements. Common types of paperboard used for making tear-open boxes include:



CCNB (Clay Coated News Back): CCNB is a paperboard material with a clay-coated side that offers excellent printing quality. It is commonly used for tear-open boxes where vibrant graphics or branding are essential.


SBS (Solid Bleached Sulfate): SBS is a premium-grade paperboard known for its smooth and glossy surface. It provides a high-end look and is often used for luxury product packaging.


C2S (Coated Two Sides): C2S paperboard features a coating on both sides, making it versatile for printing and suitable for tear-open boxes that require a polished appearance.


Natural Brown Kraft: Natural brown kraft paperboard is unbleached and has a rustic, eco-friendly appearance. It is often chosen for tear-open boxes aiming for a more organic and environmentally-conscious image.


White Kraft: White kraft paperboard offers a clean and crisp look, making it suitable for a variety of products, especially those with a minimalist or sophisticated design.


Black Kraft: Black kraft paperboard provides a unique and elegant option for tear-open boxes, often selected for high-end or fashion-oriented items.


Specialty Paper: Specialty paperboards encompass a wide range of options, including textured, metallic, or patterned surfaces, which can be chosen to create customized and distinctive tear-open box designs.


The thickness of the paperboard used for making tear-open boxes typically falls within the range of 250g to 400g per square meter (gsm). This range ensures that the material is robust enough to maintain its shape and protect the contents while still allowing for ease of folding and opening. The choice of paperboard weight depends on the specific requirements of the product being packaged, including its weight, fragility, and the desired level of protection during handling and shipping.


2.1.2 Cardboard Tear Open Boxes


Cardboard is a thicker and more durable material compared to paperboard. It exhibits a three-layer composition, encompassing an inner fluted layer embraced by two flat linerboards. Cardboard tear-open boxes are commonly used for packaging heavier or bulkier items that require extra strength and protection during shipping and handling. These boxes are often used for packaging electronics, appliances, automotive parts, and other products that need robust packaging.



Linerboard Options:


Kraft Linerboard: Kraft linerboard is made from 100% recycled materials and boasts a classic brown appearance. It’s an excellent choice for promoting organic or eco-friendly products. However, it’s important to note that bright colors printed on kraft may appear more subdued due to the natural paper color.


Standard White Linerboard (Whitetop): Standard white linerboard features a matte finish and complements various color schemes, making it versatile for different design needs. It is particularly suitable for accommodating color-intensive images compared to kraft.


Premium White Linerboard (CCNB – Clay Coated News Back): Premium white linerboard is known for its delicate coating, which imparts heightened brightness and glossiness. It is ideal for showcasing vibrant full-color designs, ensuring that a diverse and bold color palette stands out impressively.


Inner Corrugated Sheet:


Corrugated sheets offer options with single fluted layers and double fluted layers. When crafting common tear-open boxes, it is recommended to use a single fluted layer. Excessively thick corrugated sheets can hinder folding and assembly, impacting packaging efficiency. Commonly used corrugated types for tear-open boxes include:


B-flute: Provides good strength and crush resistance. Suitable for various applications.


C-flute: Offers higher stacking strength and cushioning. Ideal for protecting fragile items.


E-flute: Known for its thin profile and excellent printability. Suited for packaging with intricate designs.


For tear-open boxes designed for shipping purposes, it’s advisable to use corrugated sheets with double fluted layers. Common combinations include F/E flute, E/B flute, E/C flute, and B/C flute. The choice of corrugated thickness should be based on the fragility and weight of the product being packaged.


2.2 Classified By Structures


Mailer Box: Mailer boxes are designed for easy assembly and secure closure, making them ideal for shipping and e-commerce packaging. They often have a tear strip for easy opening. These boxes are suitable for shipping various products such as clothing, books, cosmetics, and smaller electronic devices.



Display Box: Display boxes are designed to showcase products on store shelves even after opening. They usually have a front flap that can be opened and reclosed. These boxes are great for retail packaging of items like chocolates, toys, cosmetics, and electronics.


Flap Box: Flap boxes are characterized by their flaps that fold over to close the box. They can have a tear-open feature for convenient access. Flap boxes are versatile and can be used for packaging a wide range of items, including apparel, accessories, and small household goods.


Truck Box: Truck boxes have a unique shape resembling a truck or a vehicle. They are often used for promotional packaging and can have a tear-open feature for added convenience. These boxes are great for packaging toy cars, promotional merchandise, or novelty items.


Pillow Box: Pillow boxes have a curved shape, resembling a pillow. They are easy to assemble and often have a tear strip for opening. Pillow boxes are ideal for packaging small gifts, jewelry, party favors, and cosmetics.



Book Style Box: Book style boxes have a hinged lid and open like a book. They provide a luxurious and elegant packaging solution. These boxes can be equipped with a tear-open feature for added functionality. Book style boxes are commonly used for packaging high-end items like watches, jewelry, and luxury clothing.


Sleeve Box: Sleeve boxes consist of a sliding outer sleeve and an inner tray. They can have a tear strip for easy access to the contents. Sleeve boxes are suitable for products that require a premium presentation, such as perfumes, candles, and gourmet chocolates.


Gable Box: Gable boxes have a unique shape with a built-in handle, making them convenient for carrying. They can also include a tear strip for opening. Gable boxes are often used for packaging food items, party favors, and gift items.


Drawer Box: Drawer boxes have a sliding drawer that can be pulled out from a sturdy outer sleeve. They can include a tear strip for easy access. Drawer boxes are suitable for packaging luxury items, electronics, and gift sets.


These tear-open box types offer a variety of options for packaging different products while providing convenience and functionality to both retailers and customers. The choice of box type should align with the specific product’s size, shape, and packaging requirements.


2.3 Importance of imprinting visuals


Imprinting a brand’s logo and elements on tear-open boxes is vital for brand recognition, professionalism, and marketing. It sets your brand apart in a competitive market, fosters trust, and conveys essential product information. It boosts recall, encourages repeat purchases, tells your brand story, creates a premium image, enhances online presence, and ensures compliance with regulations.


2.4 Other Creative Design Elements


To create an unmatched unboxing experience, we introduce a range of innovative design elements that elevate your tear-open boxes to a level of artistry:


Window Patch: Offer a tantalizing glimpse inside, sparking excitement and anticipation as recipients catch a sneak peek of their eagerly awaited treasures.



Zippers: Seamlessly blend functionality with aesthetics by integrating zippers. These not only provide effortless access to contents but also ensure items remain secure during transit.


QR Codes: Forge a connection between the physical and digital worlds by incorporating QR codes. These codes enable interactive experiences that link customers directly to your brand’s online presence, adding a new dimension to the unboxing process.


Handle: Infuse practical elegance into your packaging. Incorporate handles that enhance portability and aesthetic appeal, ensuring your mailer boxes are easy to carry while exuding sophistication.



Sleeves: Elevate visual allure while bolstering protection with sleeves that envelop your mailer boxes. This extra layer not only adds an element of safeguarding but also provides additional branding opportunities to captivate your audience.


Chapter 3: Tear Strips


Tear strips on tear-open boxes come in various types, each designed to provide a specific opening mechanism or user experience. Here are 2 common types of tear strips used on tear-open boxes:


3.1 Die-Cut Tear Strip


Die-cut tear strips are engineered with precision, featuring a specialized cut or groove in the packaging material that facilitates easy tearing along a predefined path. These tear strips are employed on a wide range of packaging solutions, including boxes for electronics, toys, and household goods. The die-cut design ensures that users can effortlessly follow the intended tear line, making the opening process intuitive and user-friendly. This type of tear strip enhances the overall unboxing experience, ensuring that consumers can access the product inside with ease.



3.2 Pull Tab Tear Strip


Pull tab tear strips are characterized by a small, user-friendly tab or extension typically made from durable PVC material. Users can easily grip and pull this tab to initiate the tearing process. These tear strips are frequently employed on packaging for items like snacks, beverage cartons, and resealable pouches. The PVC pull tab provides a secure and comfortable grip, allowing consumers to open the packaging without the need for additional tools. It ensures quick and convenient access to the contents while maintaining the integrity of the package. This tear strip design is particularly well-suited for products that require repeated access and resealing, making it a popular choice for resealable packaging solutions.



The tear strip may seem simple, but its production places high demands on the operator. We aim to ensure that the tear strip can be torn off cleanly and sharply while also being resistant to tearing due to external forces during transport. Typically, operators must adjust the machinery while conducting tear tests to achieve an ideal balance.


Chapter 4: Postpress Enhancements


For an added touch of elegance and sophistication, consider incorporating post-press enhancements into your tear-open boxes.


The post-printing enhancement process can often achieve more unique colors, gloss, and textures (such as UV, hot stamping, glitter, and laser effects) or even three-dimensional relief effects on a flat surface (through embossing, silk screening, etc.). Processes like lamination can both enhance the appearance and protect the printing surface. Moreover, these processes can be combined on the same packaging, allowing designers to think more freely, boldly, and precisely. Of course, achieving the best combination may require the assistance of professional craftsmen.


4.1 Spot UV



Enhance your packaging with spot UV, an impressive post-press technique that gives a glossy shine to specific elements like your company logo and printed images, improving the overall aesthetics and adding a touch of refinement. This modern and elegant finish distinguishes your product on store shelves and captivates the audience, making your brand stand out. UV, a surface treatment technology for printed materials, utilizes the high temperature of ultraviolet light to quickly dry UV ink on the paper’s surface.


You can select different UV inks for a variety of colors and glossy effects, and design treatments for different areas, including full-sheet or spot UV. Quality assessment of the UV effect focuses on ensuring a smooth surface for a mirror-like finish and thorough curing, so the UV-treated surface remains unscratched and intact under pressure and wear.


4.2 Foil Stamping



Delve into the intricate art of foil stamping to imbue your items with texture, luminosity, and captivating aesthetics. Foil stamping offers a range of choices, including metallic, pigment, or holographic foil, each contributing a unique and enchanting effect that elevates your packaging’s allure. Beyond its visual appeal, foil stamping is remarkably durable, enduring variable climates and the test of time, ensuring your packaging radiates enduring brilliance over extended periods.


The consumables used in hot stamping, such as aluminum, contain real metal materials, giving them a metallic luster and texture that is unmatched by other current technologies.


4.3 Embossing & Debossing



Craft a visual and tactile masterpiece with embossing and debossing. Embossing raises elements on your packaging, drawing attention and setting your product apart. Conversely, debossing adds a recessed texture, offering a unique tactile experience. In a competitive packaging market, these techniques help your brand stand out and add a touch of style and texture to otherwise flat surfaces.


This technique adds three-dimensional effects to the printed surface, resulting in both visual and tactile enhancements. If we incorporate elements like embossment, shadows, and textures into the design, it can lead to a realistic realization of these features.


4.4 Glitter Printing



Infuse your products with dazzling sparkle and shine through glitter printing. This special technique transforms your packaging into an eye-catching masterpiece, perfect for standing out on store shelves. From jewelry containers to cosmetic cases, glitter printing adds a touch of prestige and enthralls your customers, leaving a lasting impression. Tailor your design to showcase your product’s best features and instantly captivate your audience.


Chapter 5: How are tear open boxes made


5.1 Printing


The initial phase in manufacturing tear-open boxes is the printing process. We utilize flexography printing for kraft paperboard and offset printing for white paperboard. These advanced printing techniques, combined with state-of-the-art technology and equipment, guarantee that your design is presented with vibrant colors and sharp details.


We take color accuracy seriously and, to achieve the perfect result, we perform multiple rounds of color calibration and adjustments during the pre-production stage. This meticulous process ensures that your boxes will flawlessly showcase your brand identity and design in a striking and precise manner.


Moreover, if you desire specific visual enhancements such as spot UV coating, glitter, or foil stamping, we meticulously apply these finishing touches after the printing phase to add an elegant and sophisticated touch to your packaging.


5.2 Composite (For Corrugated Boxes)


For corrugated cardboard boxes, an additional compositing step is essential. We combine two pieces of brown or white cardboard with a corrugated sheet, using a robust adhesive to create a single, durable piece. This composite is then flattened under heavy pressure to prevent bending and deformation.


The composited cardboard undergoes a natural drying process for about two days to enhance cohesion between the materials.


Laminating is a common gluing operation in paper packaging, involving processes like corrugated and cardboard laminating. This method allows for the combination of various printed materials, significantly enriching the design and structure of the packaging. For standard cartons and color boxes, this gluing is executed with skill and stability. However, fine laminating packaging presents a challenge, requiring consistent results under various temperatures and humidity levels to prevent detachment, bubbling, wrinkling, or glue overflow. Fortunately, our mature team and extensive experience ensure successful outcomes.


5.3 Die-cutting


Die-cutting is a critical step that significantly influences the appearance and functionality of tear-open boxes. Custom shapes are precisely cut out using a die, which includes sharp blades for cutting edges and blunt blades for creases. If you opt for a tear line, it’s also achieved during this process.


Before mass production, our skilled technicians conduct multiple sampling inspections to ensure that the die’s pressure is precisely calibrated. This prevents the cardboard from being overly pierced, minimizing waste. Our experts thoroughly test each step to ensure that every box is manufactured to perfection.


To maintain the highest quality standards, our machines are regularly cleaned, guaranteeing that the finished products are free from defects like rough edges. Your tear-open boxes will be flawlessly crafted to meet your specifications and exceed your expectations.


5.4 Box Cutting


The penultimate step involves giving shape to the boxes by removing offcuts. While this step may seem straightforward, it requires expertise, as it directly impacts the quality of the final product. We employ specialized equipment for this purpose.


5.5 Box Gluing


The final step is box gluing, which is executed with the help of professional equipment. If you’ve chosen a pull tab tear strip, it is also integrated during this step. The result is a completed tear-open box, ready to impress.


Chapter 6: Eco-friendliness of tear open boxes



In recent years, the global concern for environmental issues has prompted a reevaluation of packaging materials and their impact on the planet. Tear open boxes have gained popularity due to their convenience and functionality, but how do they stack up in terms of eco-friendliness?


6.1 Are Tear Open Boxes Recyclable?


Compared with plastic packaging, tear open boxes, which are paper based, are a much more eco-friendly option, as paper is taken from nature, and will be returned to nature. And it’s biodegradable and compostable. But before it goes back to nature, it can also be recycled for several times.


Paper based tear open boxes are generally recyclable, but if it features with plastic tear strip, this part shall be recycled seperatly. Also, post-press coatings such as UV or foil stamping can also complicate recycling processes.


So it’s essential for manufacturers and consumers to be aware of the recycling guidelines in their region and make informed decisions regarding the disposal of packaging. Additionally, efforts should be made to design tear open boxes with easily separable components, making recycling more efficient.


6.2 Tear Open Boxes Made of Recycled Materials


One of our promising steps toward eco-friendliness is the use of recycled materials in the production of tear open boxes. By incorporating post-consumer recycled materials,we can reduce the demand for virgin resources and minimize the environmental impact of production.


The use of recycled materials not only conserves resources but also reduces energy consumption and greenhouse gas emissions associated with manufacturing.


6.3 Certifications from Authorities


Certifications from environmental authorities play a pivotal role in assessing the eco-friendliness of packaging materials. Organizations such as the Forest Stewardship Council (FSC) and the Sustainable Forestry Initiative (SFI) provide certifications for sustainable sourcing and responsible forest management. Tear open boxes that carry these certifications can be considered more environmentally friendly.


With the development of China, our material suppliers have become excellent manufacturers, all holding relevant qualifications and certifications (such as FSC and RoHS). This enables us to offer our customers greater peace of mind.


Chapter 7: How much are tear open boxes?



7.1 Prices of Tear-Open Boxes


Whether you choose paperboard boxes or cardboard boxes, the decision to incorporate a tear strip, whether it’s a precision die-cut or a user-friendly plastic pull tab, offers a cost-effective advantage. This addition not only enhances the functionality of your packaging but also does so without significantly impacting your budget.


Tear-open boxes strike an ideal balance between affordability and user convenience, making them an increasingly popular choice in the packaging industry. By providing an easy and efficient means of accessing the contents, tear strips add value to your product while keeping production costs in check, making them a smart and budget-friendly packaging solution for businesses of all sizes.


7.2 Factors that Influence Prices



The type of material used for your tear-open boxes is a key price influencer, for example:

SBS (Solid Bleached Sulfate) vs. CCNB (Clay Coated News Back): SBS tends to be more expensive compared to CCNB. CCNB is a common choice for cost-effective tear-open boxes.


Specialty Paper vs. Non-specialty Paper: Specialty paper, which includes unique textures or finishes, often comes at a higher price point compared to standard paper options.


Corrugated Sheets: Incorporating corrugated sheets into your boxes will increase production costs due to the added material and complexity.


Box Size and Style:

The size and style of the tear-open box play a significant role in determining its price. Larger boxes require more materials and labor, making them more expensive. Additionally, complex box styles, such as those with intricate folds or custom die-cut shapes, can increase production costs.


Printing and Branding:


Custom printing, logos, and branding elements on your tear-open boxes can have a considerable impact on the price. Options like full-color printing, embossing, foil stamping, or the use of specialty inks add to the cost. Simpler one-color designs are typically more budget-friendly.


Quantity Ordered:


The quantity of tear-open boxes ordered is also a critical factor affecting the price. Economies of scale come into play with larger order quantities. Ordering in bulk often results in lower unit prices, reducing the overall cost per box. Conversely, smaller orders tend to be more expensive on a per-unit basis.


Customization and Complexity:


The level of customization and complexity in the design of your tear-open boxes can increase costs. Features like custom inserts, window cutouts, or unique closures add to the overall price but can enhance the presentation and customer experience.


Chapter 8: Package N’ Go makes it possible


With over two decades of experience, Package N’ Go is your trusted source for high-quality tear-open boxes and packaging solutions. Our commitment to innovation and sustainability is reflected in our products. We understand the importance of packaging as a brand identity tool. Choose Package N’ Go as your packaging partner and elevate your brand with convenient, functional, and aesthetic packaging. Contact us today, and let’s start a journey that leaves a lasting impression on your customers. Package N’ Go – where packaging is a statement of quality and excellence.


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.

Everything You Need to Know About Custom Poly Mailers

Table of Contents

Chapter 1: Understanding poly mailers


1.1 What is a poly mailer?


Poly mailers, commonly known as plastic shipping bags or poly bags, are one of the most popular packing options on the market right now. They are ideal for shipping a variety of items because of their light weight, toughness, and waterproofness. Moreover, their self-sealing capability removes the requirement for additional tape during the packaging process.


The poly mailer market is anticipated to grow at a predicted pace of 4.70% from 2021 to 2028, reaching a valuation of roughly USD 1.69 billion as a result of their advantages and the expanding global e-commerce industry.


1.2 What are poly mailers made of?



Polyethylene, also known as polythene, is the most commonly produced plastic and serves as the primary raw material for manufacturing poly mailers. It is a crucial component in the plastics market, accounting for 34% of the total production with over 100 million tonnes annually.


Poly mailers are made using two main types of polyethylene: Low-Density Polyethylene (LDPE) and High-Density Polyethylene (HDPE).


LDPE poly mailers are known for their flexibility and stretchability, making them ideal for shipping items that require extra space, such as clothing, textiles, or soft goods. They have a lower density, giving them a softer touch, and a lower melting point. These mailers are non-toxic, tear-resistant, and offer high transparency.


On the other hand, HDPE poly mailers are sturdier and provide better puncture resistance, making them suitable for shipping items that need extra protection, like electronics or small gadgets. HDPE has a higher density, contributing to its harder texture and increased durability. These mailers can withstand higher pressures and have a higher melting point compared to LDPE, but they are less flexible.


1.3 What items can be shipped with poly mailers?



From clothing to electronics, poly mailers can handle a multitude of objects with ease. They are especially useful for lightweight and non-fragile items, but can also handle larger and bulkier goods. The items that can be shipped with poly mailers are mainly:




            Fabrics and yarns

            Phone cases




            Books and other printed materials


            Arts and prints


1.4 What are the benefits of poly mailers?



Easy packing and stress-free opening


The poly mailer features a peel-and-seal adhesive closure, maximizing packing efficiency and providing consumers with a stress-free opening experience.




These high-quality poly mailers are designed to be lightweight, reducing shipping costs.




Poly mailers are thin and foldable, making them a space-saving solution for businesses seeking to maximize storage areas.


Durable and penetration resistant


The poly mailers are made from durable materials, offering exceptional protection and resistance against wear, tear, and penetration during transit.


Customization for branding


Businesses can enhance their brand presence and create memorable customer experiences by customizing poly mailers with logos or branding, ensuring packages stand out and leave a lasting impression.


1.5 Does USPS accept poly mailers?


The answer is YES!


The United States Postal Service (USPS) and many other postal services worldwide accept poly mailers for shipping.


USPS First Class Mail


This service is suitable for packages weighing 13 oz or less, making it the most economical option for shipping lightweight items.


USPS Priority Mail


Packages weighing up to 70 lbs can be shipped using this service, and USPS is permitted to examine parcels to check their contents. Shipping charges are determined by distance and are typically predicted to take 1-3 business days for delivery.


USPS Media Mail


This cost-effective option is ideal for shipping books, CDs, and other printed materials.


Chapter 2: Eco-friendliness of poly mailers


2.1 Influence of plastic pollution



Plastic pollution has become a critical issue for humanity. We heavily rely on plastic across various industries, leading to an alarming production rate of 400 million tonnes of plastic waste annually. This trend is alarming as plastic production has outpaced all other materials since the 1970s, with a projected 1,100 million tonnes by 2050 if not curbed.


Single-use plastic items, especially packaging, contribute significantly to this crisis, with around 85 percent ending up in landfills or as unregulated waste. Moreover, the production of these plastics relies on fossil fuels, causing a substantial 19 percent of the global carbon budget by 2040.


It is clear that urgent action is needed to address plastic pollution and its harmful consequences on the environment and human health. Thus, plastic packaging recycling has become an extremely important subject.


2.2 Are poly mailers recyclable?



Yes! Poly mailers can be and should be recycled.


2.3 How to recycle poly mailers?


Recycling programs and guidelines can vary significantly from one area to another. It’s essential to be aware that not all recycling centers accept poly mailers. However, there are alternative options for recycling these materials.


Many grocery stores or big-box retailers like Home Depot, Whole Foods, and Targethave have initiated recycling projects that accept plastic bags like poly mailers. They have conveniently placed drop-off bins where customers can responsibly dispose of their plastic mailers.


2.4 Recycled poly mailers



Recycled poly mailers not only benefit the environment but also offer cost-effectiveness. They provide almost the same functionality and durability as mailers made from new materials, but they are cheaper in price.


As a business, you have the flexibility to choose between using 100% recycled materials or incorporating a certain percentage of recycled materials alongside new materials. This decision allows you to demonstrate your commitment to protecting the planet and embrace more sustainable practices in your operations.


2.5 Biodegradable and compostable options


Biodegradable poly mailers and compostable poly mailers have become increasingly popular among environmentally conscious consumers and businesses. These eco-friendly mailers are made from biodegradable polymers and bio-based components, designed to break down over time through microbial action, leaving behind natural elements.


While the prices of biodegradable poly mailers and compostable poly mailers can be up to several times the price of ordinary poly mailers.


2.6 Certifications from authorities


Eco-friendly poly mailers can obtain certifications from reputable authorities such as SGS and TUV. These certifications validate their adherence to stringent environmental standards and sustainable practices. By obtaining these certifications, businesses and consumers can have confidence in the authenticity of the mailers’ eco-friendly claims. SGS and TUV are globally recognized and trusted organizations that ensure the mailers’ materials, manufacturing processes, and overall environmental impact align with eco-friendly principles.


Chapter 3: How much are poly mailers?


3.1 Prices of custom poly mailers


If purchased in bulk from US suppliers with no special customization requirements, prices generally start at just 0.25$. However, for those looking to save even more money, overseas suppliers offer custom poly mailers in bulk with prices starting at just 0.05$.


3.2 Factors that influence prices



Material quality


The quality of the polymeric materials used in manufacturing the mailers can significantly impact the cost. Higher-quality materials may be more durable and offer better features, but they might also be more expensive.


Size and dimensions


Larger or custom-sized poly mailers will require more material and possibly more complex manufacturing processes, leading to higher costs compared to standard sizes.


Thickness and strength


Thicker and stronger poly mailers provide better protection for the contents, but they might be more expensive due to the increased use of materials.


Quantity and volume


Bulk orders typically enjoy economies of scale, leading to lower per-unit prices compared to smaller quantities.




Printed or branded poly mailers with logos, designs, or specific colors can add to the cost as they involve additional printing and setup expenses.


Chapter 4: How to customize your poly mailers?


Customizing your poly mailers to precisely match your unique marketing and shipping demands involves crucial decision-making on various aspects, such as types, materials, sizes, thicknesses, and designs.


4.1 Different types of poly mailers


Poly mailer bags come in various types based on their structure and features:


Regular self-sealing poly mailers



The standard option with no special features, suitable for general shipping needs.


Poly mailers with handles



These have die-cut handles on top for easy carrying and create a higher-grade impression on customers.


Clear-view poly mailers



Made with a transparent film on one side, allowing customers to view the contents of the package.


Wicket poly mailers



Ideal for companies with large shipment volumes, as they simplify the packaging process with tear-down function.


Returnable poly mailers



Feature double self-sealing strips, allowing the bag to be reused for future shipments, reducing plastic waste.


Poly mailers with tear strips



Have a perforated tear-off strip for easy opening.


Gusseted poly mailers



Designed with bottom and side gussets to increase loading capacity and provide extra protection for bulkier items.


4.2 What design files should be provided?


When customizing a poly mailer, you gain the opportunity to incorporate your branding, logo, and distinctive design elements, resulting in a unique and professional packaging solution. To ensure an effective design, consider the following aspects when preparing your design files.


File format


Preferred file formats for design artwork are typically high-resolution files, such as AI or PDF.




The resolution should be at least 300 DPI (dots per inch) to ensure a crisp and clear print.


Color mode



Use CMYK color mode for printing purposes, as it is optimized for four-color process printing. Avoid using RGB color mode, as the colors may not accurately translate to the printed version.




Convert all text to outlines or provide the fonts used in the design to avoid font substitution issues. This ensures that the text appears exactly as intended in the final print.


Graphic elements


Provide the links and ensure that all graphic elements (logos, images, icons) are high-quality and properly positioned within the design. Avoid using copyrighted images without proper authorization.


4.3 Tips for designing custom poly mailers


Package N’ Go is delighted to provide you with valuable tips to achieve the finest design for all your marketing and shipping requirements.


Patterns not extending to left and right edges



Avoid placing designs all the way to the left and right sides of the mailer bags due to potential cutting machine deviations. This can lead to patterns from one side ending up on the next mailer bag’s side, ruining the overall appearance.


Patterns not extending to bottom edges


It is suggested to avoid laying patterns at the bottom edges of the front and back sides of mailer bags. Small changes during folding could cause patterns to shift, resulting in unintended placements.


Limit colors in the design


Gravure printing used for mailer bags requires overprinting and strict machine requirements. To avoid issues with inaccurate or inferior overprinting, it is recommended to use no more than four colors in the design. Spot color or monochrome may be better for small text or lines.


Keep gluing area blank


Maintain functionality and cost-efficiency by leaving the adhesive area of the poly mailer free from any decorations. Keeping this area clean ensures a strong adhesion, prevents ink from compromising the adhesive quality, and avoids covering the decorations after the mailer is sealed.



Eye mark or locator mark


Finished mailer bags may have an eye mark or locator mark, a small black line strip that aids automatic cutting machines in precise trimming. Designers should be aware of this element, even if it wasn’t part of their original design.


Chapter 5: How are poly mailers made?


The production process of poly mailers primarily involves three main stages: film blowing, printing, and bag making.


5.1 Film blowing


Film blowing is a plastic processing method used to produce films by melting plastic particles and blowing them into a tubular film. High-pressure air inflates the film to the desired thickness. After cooling, the film is finalized. The film-blowing machine is crucial in this process, producing high-grade film packaging with excellent barrier properties, freshness preservation, and more.


Poly mailers, commonly used for shipping, are made of three layers of co-extruded film, offering advantages like transparency, puncture resistance, and heat sealing properties. The inner layer is often black or gray for confidentiality, while the outer layer is light gray. Customization options allow for specific design modifications.


5.2 Printing


Poly mailer bags are printed using a specialized gravure press, ensuring high-quality results. The process involves transferring the design onto a copper plate using gravure printing, ensuring precise ink application to designated areas. The inked plate is then pressed onto the co-extruded film to complete the printing process.


5.3 Bag cutting and bag making



After ensuring the printings meet the desired quality, the production moves to the final step of creating the poly mailer bags – bag cutting and bag making. In this stage, the co-extruded film is first laminated with the adhesive strip. The bag-making machine’s knife head then precisely cuts and heat-seals the film to create the poly mailer envelopes.


The hot melt adhesive used in this process plays a crucial role. It must possess specific characteristics like good initial adhesion, strong holding force, and resistance to oil seepage. Once bonded, the adhesive ensures the poly mailer cannot be easily torn, providing anti-counterfeiting and anti-theft functions. Therefore, selecting the right hot melt adhesive is essential for the bag-making process to ensure the production of high-quality poly mailer bags.


5.4 Turnaround


The turnaround time for custom poly mailers can vary based on several factors. In general, larger quantities and more intricate designs or techniques will necessitate a longer production period.


For instance, if a factory is producing 50,000 standard poly mailers without any customizations, they typically have readily available materials in stock, enabling them to complete the production in approximately 7 days. However, when it comes to the same quantity of custom sized poly mailers with 4-color printing, the factory needs to undertake plate making and material preparation, leading to a longer production time of around 15 days.


Chapter 6: How to do the quality inspection for poly mailers?


During and after the production process, quality control measures are meticulously incorporated into every session.


6.1 Why is quality inspection important?



Quality inspections for poly mailers are essential to maintain product integrity during transit, preventing any defects or weaknesses that could lead to damage to the items inside. They ensure customer satisfaction by providing a positive unboxing experience and avoiding negative reviews and potential loss of business. Additionally, inspections save costs by identifying and eliminating faulty mailers before shipping, while also upholding a brand’s reputation for professionalism and commitment to quality. Moreover, inspections enhance supply chain efficiency by addressing issues early, ensuring smooth manufacturing to delivery processes.


6.2 How many samples will be inspected?



To ensure strict adherence to quality requirements, we employ the AQL (Acceptable Quality Limit) inspection procedure. This involves randomly selecting a set number of samples from each batch and comparing them to established acceptance criteria. The number of samples inspected is determined by the order quantity and the required degree of inspection.


The AQL inspection consists of two parts: special inspection and general inspection. If the client does not have specific requirements, we typically use the standard criteria: CRITICAL DEFECT=0, MAJOR DEFECT=2.5, and MINOR DEFECT=4.0. A minor defect does not significantly impact product use, while a major defect might render it unsuitable for its intended purpose. A critical defect can be hazardous or even fatal if left unaddressed.


Special inspection, following the S-4 standard, primarily focuses on functional issues. We maintain a zero-tolerance policy for functional problems, and the discovery of even one bag with critical defects leads to the rejection of the entire batch. Functional issues may include severe stains like insects, blood, hair, or other dirt, as well as the presence of hazardous items such as blades. Additionally, poor sealing edge firmness and adhesive sealer firmness are considered severe problems that significantly affect user functionality.


For general inspection, we often use the level II criteria. Suppose the order quantity is 8000, corresponding to word code L with a sampling number of 200. In this case, MAJOR DEFECT=2.5 and MINOR DEFECT=4.0. The corresponding AC values for 2.5 and 4.0 are 10 and 14, respectively. Thus, among the 200 randomly selected bags, if there are no more than 10 bags with major defects and no more than 14 bags with minor defects, the batch is considered acceptable.


By employing the AQL inspection, we ensure that every batch of poly mailers meets stringent quality standards, providing our clients with high-quality products that meet their expectations and specifications.


6.3 Quality inspection criteria


Poly mailer dimensions


Accurate measurements are crucial for poly mailers. The length and width must be carefully examined during the inspection, with a strict 3mm tolerance to avoid any issues. Providing precise dimensions ensures a successful outcome and prevents costly setbacks.





To maintain the highest standard, the product’s thickness is tested using a professional micrometer. It must fall within the specified range, like a +/- 0.4cmm margin for 6cmm thick poly mailers. Deviations outside this range result in the package being deemed unfit for purchase.


Film color


Quality assurance for poly mailers goes beyond the human eye. Advanced equipment is used to ensure the colors meet stringent expectations, guaranteeing only quality products for consumers.


Ink saturation


Achieving a professional look requires optimal ink saturation. Even and consistent ink coverage is essential, striking a balance between being too dull or too bright. This level of perfection ensures neatness and meets professional standards.


Ink adhesion


Two methods are employed to evaluate ink adhesion. The printing surface is covered with special tape and slightly stretched to measure adhesion strength accurately. Rubbing the surfaces together also provides information about effective ink adherence.


Film stretching force



Poly mailer film’s stretching ability is vital to ensure it can securely hold its contents. In-house evaluation verifies the polymer film’s tensile strength both vertically and horizontally, ensuring it performs as intended.


Edge sealing firmness


Edge sealing significantly impacts strength, durability, and safety compliance. A violence test evaluates the seal’s effectiveness under different force levels. This ensures superior poly mailers that meet industry standards and perform well.


Adhesive sealer firmness



The poly mailer sealer must be firm to keep items secure during transit, preventing wear and tear or damage. This layer of defense ensures the items arrive at their destination in optimal condition.


Carton details


Thoroughly inspecting cartons containing poly mailers is crucial. The QC team checks for the correct number of bags, undamaged cartons with clear markings, and proper sealing. Weight is also verified to ensure it meets the required limits.


Stack details


During inspection, stack details are closely checked. The legs of the stack must be complete and aligned, with proper wrap-around films and tapes to protect the cartons. Ensuring complete protective corners guarantees the products’ safe arrival in perfect condition.


6.4 Who does the quality inspection for you?


Quality inspection from the supplier


At Package N’ Go, we have a dedicated team of highly qualified experts and state-of-the-art facilities for quality inspection. Our team is trained to identify even the smallest flaws to ensure that every delivery meets high standards. We provide complete transparency and issue comprehensive inspection reports to give our clients peace of mind.


Quality inspection from a third party


For those seeking extra assurance, we offer the option of third-party inspections. We work closely with reputable inspection institutions to ensure the validity and thoroughness of their analyses, resolving any difficulties promptly. You can rely on our support throughout the process if you opt for a third-party examination.


Some of the reputable inspection institutions we collaborate with include:

SGS: A highly regarded global organization with over 90 branches and 200 laboratories worldwide. Their 15,000+ skilled specialists provide quality assurance and a trusted seal of approval.


TUV Rheinland: A global leader in product inspection and certification, with over 130 years of experience. The German Technical Inspection Agency Network (TUV) maintains high-quality standards across 30+ countries. Their rigorous test methods ensure only top-notch safety and quality products enter the market.


Chapter 7: Conclusion



We have covered every aspect of custom poly mailers in depth in this extensive guide. With a cutting-edge supply chain focused in China, Package N’ Go is a reputable American company with a global presence. We have developed into a renowned leader with more than two decades of experience thanks to our unrelenting dedication to providing custom packaging solutions.


We take pride in providing a wide selection of custom packaging goods, such as custom bubble mailers, custom boxes, and custom poly mailers. Whether you are a startup or a large company, Package N’ Go is completely prepared to meet your specific needs. With 10,000 mailer bags and 500 boxes, our extremely low minimum order quantities (MOQ) are the industry standard. Contact us right away to take advantage of Package N’ Go’s outstanding packaging options.

The Ultimate Guide to Mailer Box

Table of Contents

In the ever-evolving world of commerce, packaging is no longer just a means to an end. It has transformed into a powerful tool that influences customer perceptions, enhances brand identity, and elevates the entire shopping experience. At the heart of this packaging revolution lies the mailer box – a versatile and sturdy solution that has captured the attention of brands across industries.


This guide is your one-stop resource to mastering the art of mailer boxes, and we will embark on a journey into the realm of mailer boxes, exploring their significance, advantages, materials, customization options, and much more.


So, if you’re ready to delve into the world of packaging innovation and discover how mailer boxes can revolutionize your business, let’s begin this enlightening exploration.


What Is a Mailer Box?


A mailer box is a specialized paperboard packaging solution designed for storing and shipping products. Its innovative design features interlocking flaps and wings, allowing for easy assembly and closure without the need for adhesive tape. With its double-sided walls, it offers enhanced durability and resistance during transportation, making it a reusable option.


This versatile and robust packaging solution goes beyond conventional shipping containers. It is carefully crafted to ensure the secure transit of products from sellers to end consumers, offering remarkable protection against potential external impacts that products might face throughout their journey. Typically crafted from corrugated cardboard, this packaging marvel guarantees exceptional safeguarding of items.


Why The Right Mailer Box Is Crucial


Importance of Mailer Box


When customers make a purchase, they aren’t just buying the product itself; they’re investing in the entire experience. From the enticing product images online to the smooth checkout process and order confirmation, right through to receiving the package and unboxing it – every step contributes to the overall experience.


Now, you might be wondering, why choose a mailer box specifically? Well, the answer lies in the advantages of mailer box.



Advantages of Mailer Box


Cost-Effective Shipping


These boxes are superheroes when it comes to shipping! Lightweight yet strong, they keep your shipping costs in check. Plus, their compact design helps save space in storage, making them an economical choice for businesses.


Unforgettable Unboxing Experience


Let’s face it; the moment of unboxing is a big deal! Mailer boxes are masters at making it a memorable experience. Customers can’t wait to tear open the box and be greeted with a beautifully presented package. It’s like unwrapping a gift and leaves them feeling super happy! They might even share their excitement on social media, spreading the love for your brand!


Enhanced Brand Visibility


Mailer boxes offer a unique canvas for showcasing your brand identity. With ample surface area for logos, designs, and promotional messages, they create a powerful branding opportunity. As your packages journey through transit and arrive at their destinations, your brand’s presence is consistently reinforced, increasing brand recognition and recall.


Efficient Storage and Inventory Management


Mailer boxes are designed with efficiency in mind. Their stackable and space-saving nature optimizes storage capacity, allowing businesses to manage inventory seamlessly. With uniform sizes and easy identification, organizing and accessing products become streamlined, contributing to smoother operations.


Convenient Returns and Exchanges


Mailer boxes play a crucial role in the reverse logistics process. Should customers need to return or exchange products, these boxes simplify the procedure. Their easy-to-open design and secure closure make repackaging hassle-free, enhancing the overall customer experience and fostering customer loyalty.


Types Of Mailer Box


Classified By Material


A mailer box exhibits a three-layer composition, encompassing an inner fluted layer embraced by two flat linerboards.

Flat Linerboards


Kraft: Diverse linerboard options are at your disposal for crafting mailer boxes, with prominent selections including kraft, standard white, and premium white.


Derived from 100% recycled materials, kraft linerboard boasts a timeless brown aesthetic. Particularly suited for promoting organic products, it’s an ideal choice. However, it’s worth noting that bright colors printed on kraft may exhibit a more subdued appearance.


Standard White: Often referred to as whitetop, standard white linerboard features a matte finish. It seamlessly complements all color schemes, making it versatile for various designs. Notably, standard white is more adept at accommodating color-intensive images compared to kraft.


Premium White: Recognized as CCNB, premium white linerboard boasts a delicate coating that imparts heightened brightness and glossiness. This variant shines brightest when showcasing vibrant full-color designs. Opt for premium white to ensure the vividness of your diverse and bold color palette stands out impeccably.

Inner Corrugated Sheet


Corrugated boxes offer both single fluted layers and double fluted layers as options. However, for mailer boxes, a single fluted layer is recommended, as excessively thick corrugated sheets can hinder folding and assembly, affecting packaging efficiency. The commonly used corrugated types for mailer boxes include B-flute, C-flute, and E-flute. Opt for the appropriate thickness based on the fragility of your product.


Corrugated boards can be selected for various product packaging and transport needs, and they can also be combined with different flat boards to achieve a multitude of structural designs and appearance effects. The selection of corrugated board type is crucial as it determines the strength, durability, and protective qualities of the packaging.


Classified By Style


Tab Lock Roll End: The Tab Lock Roll End mailer box features a roll end design for secure closure, and it also includes tabs that lock into place, providing additional strength and stability.


Roll End 3 Flaps Tuck: The Roll End 3 Flaps Tuck mailer box has three flaps on the top lid that tuck into the front panel, creating a secure closure.


Roll End Tuck Top: The Roll End Tuck Top mailer box features tuck flaps on the top lid that fold inward and tuck into the front panel, providing a reliable and convenient closure.


Roll End Tuck Front: The Roll End Tuck Front mailer box has tuck flaps on the front panel that fold inward and tuck into the top lid, securing the box for transit. This design is often chosen for products that require a tamper-evident closure.


Materials of Mailer Box


Recyclable Materials


At the forefront of our commitment to environmental responsibility, we proudly offer mailer boxes constructed from 100% recycled corrugated sheets. By utilizing these recyclable materials, we contribute to the reduction of waste and the conservation of valuable resources. This choice not only aligns with sustainable practices but also ensures that our packaging solutions meet the highest standards of eco-friendliness.


Suggestions on how to choose material


Lightweight and Soft Products:


If your products are relatively light and not prone to damage, a cardboard box can be a suitable option. Cardboard provides a cost-effective solution for packaging items like clothing, stationery, or non-fragile goods. This type of mailer box typically uses 180-350g/m² white cardboard, kraft paper, or white board paper.


Moderate Weight and Fragile Items:


For products that are a bit heavier or fragile, corrugated mailer boxes are the way to go. Corrugated cardboard consists of a fluted inner layer sandwiched between two linerboards, providing excellent strength and protection against impacts and compression.


The most commonly used types are three-layer B-flute, three-layer E-flute, and three-layer C-flute corrugated boards. Among these, the three-layer C-flute is thicker and softer, making it most suitable for the outer box of lightweight transport packaging to enhance cushioning and increase safety. On the other hand, E-flute boards are light, thin, and stiff, with relatively poor single-layer cushioning, making them ideal for packaging small items or even for art packaging purposes. They can be crafted into folding boxes to improve their cushioning performance. B-flute boards, positioned in terms of thickness and stiffness between C-flute and E-flute, offer versatility as they can be utilized both as primary packaging and as outer boxes.


Linerboard Weight:


The linerboard, which is the flat outer layer of corrugated cardboard, contributes to the box’s appearance and print quality. To maintain a professional and polished look, choose linerboard with a weight of over 140g. Lighter linerboard may allow the corrugated sheet’s ridges to show through, affecting the overall aesthetics. For varied packaging and transport requirements, selecting different thicknesses and types of linerboards is an option. These linerboards, enhanced through printing and post-press processing, can be adhered to corrugated paper to augment its thickness and stiffness. This enhancement not only provides additional structural support but also enriches the packaging design.


Custom Options


Size and Material


Recognizing the uniqueness of each product’s dimensions and protection needs, we provide the flexibility to select the ideal size for your mailer boxes. Whether it’s the robust corrugated cardboard for heightened security or the lightweight paperboard for cost-effective options, you have the freedom to choose the material that best aligns with your requirements.


Shape and Style


Give your mailer boxes a unique look with various shape and style options. Whether you prefer a traditional rectangular shape or a more unconventional design, we have the expertise to craft the perfect box that aligns with your brand aesthetics.


Imprinting Visuals


Imprinting your brand’s identity onto the mailer boxes is a pivotal part of the customization process. Our advanced printing capabilities ensure that your logo, imagery, and messaging are vividly showcased, leaving a lasting impression on recipients. Whether you opt for a minimalist design or a bold and intricate pattern, our high-quality printing ensures your vision comes to life with precision and clarity.


Other Creative Design Elements




In pursuit of an unparalleled unboxing experience, we present an array of innovative design elements that transform your mailer boxes into works of art:


Window Patch: Offer a tantalizing glimpse inside, generating excitement and anticipation as recipients catch a sneak peek of their awaited treasures.


Zippers: Fuse functionality with aesthetics by incorporating zippers that grant effortless access to contents while safeguarding items during transit.


QR Codes: Bridge the physical and digital realms by integrating QR codes, enabling interactive experiences that connect customers with your brand’s online presence.


Handle: Infuse practical elegance, offering both portability and aesthetic appeal, ensuring your mailer boxes are easy to carry while exuding sophistication. Sleeves: Elevate visual allure while enhancing protection with sleeves that encase your mailer boxes, providing an extra layer of safeguarding and branding opportunities.


Postpress Enhancements


To add a touch of elegance and sophistication, consider postpress enhancements. Options like spot UV coating, foil stamping, embossing, or glitter accents can elevate the visual appeal of your mailer boxes, making them truly eye-catching and memorable.


The post-printing enhancement process can often achieve more unique colors, gloss, and textures (such as UV coating, hot stamping, glitter, and laser treatments) or even three-dimensional relief effects on a flat surface (such as embossing and silk screening).


Techniques like lamination can enhance the appearance and protect the printing surface. Importantly, these processes can be combined on the same packaging, allowing designers more freedom, boldness, and precision in their creations. However, determining the best combination often requires the assistance of professional craftsmen.


Spot UV


UV coating is a widely used technique that adds a glossy, durable finish to printed materials. A clear liquid coating is applied and cured with ultraviolet light, providing protection against scratches, scuffs, and fading from environmental factors.


There are two main types of UV coating: clear UV, which highlights specific patterns with a glossy varnish, enhancing visual appeal, and colored UV, which directly applies colored varnish for vibrant and impactful designs, eliminating the need for background printing. Both options offer unique ways to enhance the look and durability of your printed products.


Foil Stamping


Delve into the intricate craft of foil stamping to infuse your items with texture, luminosity, and captivating aesthetics. The process encompasses two distinct methods: hot foil stamping and cold foil stamping. From a visual presentation standpoint, foil stamping offers a trifecta of choices: metallic, pigment, or holographic foil. Each variant contributes a unique and enchanting effect that elevates your packaging’s allure.


Beyond its aesthetic merits, foil stamping boasts remarkable resilience, successfully enduring variable climates and the test of time. Thus, your packaging exudes an enduring radiance that stands unwavering over prolonged periods.


Embossing & Debossing


Embossing and debossing techniques are artful ways to enhance packaging. Embossing lifts intricate designs from the surface, adding both visual and tactile intrigue, while debossing imparts subtle texture and refined elegance. These methods elevate your brand’s image, creating a touch of luxury that engages customers on multiple sensory levels.


Varieties of Embossing & Debossing


a) Blind Embossing/Debossing


Crafting intricate designs without additional color or foil, blind embossing and debossing create understated yet captivating visuals. Debossing gently presses patterns into the material, while embossing raises them, utilizing light and shadow to showcase texture and sophistication.


b) Registered Embossing/Debossing


By combining blind embossing with ink, foil, or other embossed elements, registered embossing captures attention with a dynamic 3D effect. This technique introduces color and texture into the equation, resulting in packaging that engages the senses and leaves a lasting impression.


Glitter Printing


Glitter printing stands out as a distinctive and specialized printing method that employs real metallic glitter particles infused into the ink, yielding a luminous and attention-grabbing outcome. This technique finds its versatility in its applicability to diverse surfaces such as paper and plastic substrates, rendering it an optimal selection for an array of applications, encompassing product labels, packaging boxes, as well as decorative elements like gift wrap and tissue paper. The myriad assortment of glitter particle sizes, colors, and shapes empowers product designers with the creative latitude to conceive genuinely distinctive and captivating designs, strategically engineered to captivate the gaze of potential customers amidst the expanse of store displays.


Common Applications Of Mailer box


Mailer boxes have become a retailer’s favorite for versatile applications like gift packaging and distributing promotional materials. Retailers leverage custom mailer boxes in subscription services, catering to a range of products from makeup to video games, offering customers an exceptional experience.


In addition to subscriptions, businesses rely on mailer boxes to dispatch items like books, catalogs, and merchandise for online orders, cementing their role in modern commerce.


The widespread dispatch of mailer boxes globally highlights their significant role and usage in the retail industry.


How to Cut Cost Of Mailer box


Increase Order Quantity:


As the saying goes, “buying in bulk saves money,” and this principle applies to mailer boxes too. Increasing the order quantity can lead to significant cost savings per unit.


Opt for Cost-Effective Materials:


Choosing cost-effective materials without sacrificing quality is another way to reduce expenses. For example, opting for clay-coated news back (CCNB) instead of solid bleached sulfate (SBS) may result in a slight reduction in glossiness but still maintains a satisfactory print quality.


Reduce Thickness:


While ensuring the safety of the packaged items, businesses can consider reducing the thickness of corrugated cardboard or the weight of linerboards. Careful testing and evaluation are essential to find the optimal balance between protection and cost.


Minimize Printing Colors:


Full-color printing can add significant costs to mailer boxes. By using a limited color palette or opting for spot colors, businesses can achieve visually appealing designs while keeping printing expenses in check.


The specifics of product packaging are intricate and complex, and cost reduction should be a primary consideration; the most suitable option is often the best. Therefore, it is essential to communicate thoroughly with craftsmen during the design process to achieve the desired outcome in terms of quality and cost.


Ways of payment


Full Payment for Small Orders:


For smaller orders with limited quantities, we require full payment at the time of purchase. This straightforward payment method ensures a smooth and efficient processing of your order.


Installment Payment for Large Orders:


We understand that larger orders may require more budget flexibility, and to better serve our customers, we offer the option of installment payments for bulk purchases. With this approach, you can spread the total cost of the order over multiple payments, making it more manageable and easing the financial burden.


Diverse Payment Methods:


We offer diverse payment methods to ensure convenience and cater to different preferences, including secure Company Checks, trusted PayPal for online transactions, and a range of Major Credit Cards like Mastercard, Visa, American Express, Discover, JCB, Maestro, and UnionPay, ensuring a seamless and efficient checkout process.


How are mailer boxes made?  




The first step in creating mailer boxes is printing. Regardless of the type of cardboard you choose, adding images and logos to the mailer boxes is essential for enhancing aesthetics and leaving a lasting impression on your customers. At our company, we utilize flexography printing for kraft cardboard and offset printing for white cardboard. These printing techniques, coupled with high-end equipment and advanced technology, ensure that your design is presented at its best, with vibrant colors and sharp details.


We utilize Heidelberg and Roland presses in a variety of sizes and colors to guarantee color accuracy, speed, flexibility, and reliability.


We take color accuracy seriously, and to achieve the perfect result, we conduct multiple rounds of color calibration and adjustments during the pre-production stage. This meticulous process ensures that your mailer boxes showcase your brand identity and design in the most striking and precise manner.


Additionally, if you desire specific visual enhancements like spot UV coating, glitter, or foil stamping, we carefully apply these finishing touches after printing to add a touch of elegance and sophistication to your packaging.




Composite the two pieces of brown or white cardboard and corrugated sheet into one piece with a strong adhesive. Flattened with a heavy object, they are kept from bending and deformation.


The composited cardboard have to experience about two-day natural drying in order to strengthen the cohesion between each other.




Die-cutting is a crucial step that determines the appearance and functionality of the mailer boxes. Custom shapes are precisely cut out using a die, which consists of sharp and blunt blades to mark edges and creases respectively.


Before mass production, our skilled technicians conduct multiple sampling inspections to ensure the die’s pressure is carefully calibrated. This prevents the cardboard from being overly pierced, reducing the risk of waste. Each step is thoroughly tested by our experts to ensure that every box is produced to perfection.


To maintain the highest quality standards, our machines undergo regular cleaning, ensuring that the finished products are free from defects like rough edges. Your mailer boxes will be flawlessly crafted to meet your specifications and exceed your expectations.


Box Cutting and Making


This is the last step and the most important one, boxes begin to take shape as offcuts are removed. The step seems simple, but that requires expertise since it directly affect the box making. We have our specialist equipment to do that. After that, the two-dimensional boxes are completed. If you prefer three-dimensional ones, just tell us without hesitation. Whether to receive unfolded boxes or finished ones depends on your requirement. 


Tips For your Mailer Box 




Oversized Boxes


Is bigger always better? One-size-fits-all policies can be problematic. Correct it before it’s too late. Oversized boxes are costly for businesses and inconvenient for customers. They can also lead to product damage during transit. Opt for the right fit to avoid these issues.


Here are common size options for various items that you can select based on your needs. If you’re uncertain about choosing the right size for your products, feel free to reach out to us for assistance.


9.2×9.2×5 cm

11.8×14×8 cm


Perfect for jewelry, cosmetics, or small accessories, these compact mailer boxes will enhance the value of your products.


32×18.9×9 cm

30.2×23.3×8.8 cm

35×26×10 cm


Medium-sized boxes are highly popular for clothing items like T-shirts, dresses, blouses, trousers, and light jackets, providing an ideal fit. 


44×33.9×15.9 cm

42.5×52×18 cm


For larger electronic appliances or heavy clothing items, our spacious mailer boxes offer the perfect match.


Complicated or inadequate packaging


Consider your customers’ feelings when they receive an item buried in excessive bubble-wrap and twist ties. Difficult-to-open packaging can lead to frustration and a negative experience. Moreover, excessive packaging generates unnecessary waste, which goes against the prevailing environmental protection culture. Embrace a positive corporate culture by adopting user-friendly and eco-friendly packaging solutions for your business growth.


Incorporating minimalism is a vital strategy to make your product shine. To effectively safeguard your product while adhering to a minimalist philosophy, using inserts is an optimal choice.


Wrong materials


Choosing the wrong materials for packaging is a common mistake among manufacturers. For example, kraft cardboard is not ideal for color-heavy images, resulting in muted prints. Additionally, using single-walled cardboard that is too thin can cause damage to the box and products. Proper material selection is essential for effective branding and product protection.




Branded boxes


Using branded boxes is a powerful way to enhance your packaging strategy. A well-designed branded box goes beyond mere packaging – it becomes an extension of your brand identity. Your company logo, colors, and design elements on the box can make a lasting impression on customers.


When they receive a package that bears your unique branding, it reinforces your brand’s professionalism and commitment to quality. Branded boxes not only contribute to a cohesive brand image but also create a sense of anticipation and excitement for what lies inside. This can lead to increased brand recognition and customer loyalty as your customers associate the positive unboxing experience with your brand.


Customer experience


The unboxing experience holds significant importance in today’s consumer-centric landscape. Customers cherish the excitement of unwrapping a package just as much as the product itself. To create a memorable and delightful unboxing experience:


Customized Inserts (Internal Supports): Tailor internal inserts to fit products snugly for sophistication and optimal protection during transit. This attention to detail demonstrates care for customers’ products and overall experience.


Colorful Fillers: Include vibrant fillers like tissue paper to heighten anticipation and surprise. These add elegance and whimsy to the unboxing process, evoking positive emotions as customers uncover their purchase.


Handles for Retail: Businesses in retail environments can enhance convenience by adding handles to mailer boxes. Easy carrying and organized stacking show thoughtfulness in the customer experience. Typically, a mailer box is rectangular. For products with irregular shapes, designing a suitable inner tray can prevent the product from shaking and being damaged inside the box. The choice of materials and structures for the inner tray is diverse and can be tailored to fit specific needs.




Quality Control


Q1: How do you ensure the quality of your mailer boxes?


A1: At our company, we take quality control seriously to deliver top-notch mailer boxes to our customers. Our quality assurance process includes various steps:


Professional Testing: We employ specialized testing equipment to conduct edge crush tests, adhesive strength tests, and other relevant evaluations to ensure the boxes’ strength and durability.


The Edge Crush Test (ECT) serves as an accurate performance assessment and has a direct correlation with the ability of a carton to withstand stacking pressures. ECT gauges the resistance of corrugated board to compression along its edges. The procedure involves compressing a small section of the board vertically between two solid plates, at a right angle to the flute direction, until a maximum load is reached. The result is quantified in pounds per inch of the load-bearing edge (lb/in), but it’s commonly presented as an ECT measurement


  Bursting Test Minimum Edge Crush Test Maximum Load Per Carton
Standard 200# 32 ECT 40 lbs.
Heavy Duty 275# 44 ECT 65 lbs.
Heavy Duty – Double Wall 275# 48 ECT 80 lbs.


External Verification: We also collaborate with reputable professional testing institutions, such as SGC (Sample Goods Certification), to validate our products’ adherence to industry standards and requirements. SGC is a globally recognized certification body that specializes in assessing and verifying product quality and safety.


Q2: Can I request a sample before placing a bulk order?


A2: Absolutely! We understand the importance of evaluating our products before making a substantial investment. We offer the option to request samples of mailer boxes so you can assess their design, material, and functionality firsthand. This way, you can be confident in your choice and make any necessary adjustments before placing a bulk order.





Q3: What is the typical lead time for receiving my order?


A3: The lead time for your order depends on several factors, such as the quantity, customization options, and shipping method selected. After receiving your order details, we will provide you with an estimated lead time. We work diligently to fulfill orders promptly, and our goal is to ensure you receive your mailer boxes within the agreed-upon timeframe.


Q4: Can you handle international shipping?


A4: Absolutely! We have experience in handling international shipments and can deliver mailer boxes to customers worldwide. Our logistics network is equipped to handle international shipping requirements, ensuring smooth and reliable delivery to your desired destination.


Other Aspects


Q1: Do you offer design services for custom mailer boxes?


A1: Absolutely! Our team of skilled designers is here to assist you in creating stunning and impactful designs for your mailer boxes. Whether you have a specific concept in mind or need guidance in developing a design that aligns with your brand, we are here to make your vision a reality.


Q2: What if I need to make changes to my order after it’s been placed?


A2: If you need to make changes to your order after it has been placed, please contact our customer support team as soon as possible. We will do our best to accommodate your request, but please note that changes may not always be possible depending on the production status of your order. We recommend reviewing your order details carefully before confirming to ensure accuracy.


Q3: Can I track my shipment?


A3: Yes, we provide tracking information for your shipment so you can monitor its progress and estimated delivery date. Once your order is dispatched, we will send you the tracking details, allowing you to stay informed about the status of your mailer boxes.



To conclude, the mailer box stands as the definitive solution for expertly and elegantly shipping your products. Beyond its durability and protective qualities, these adaptable and robust packaging wonders offer an avenue to display your brand and curate an unforgettable unboxing encounter for your clientele.


Consider this: Does your packaging truly reflect the value of your product? Have you explored the full potential of design and customization to resonate with your audience? The impact of packaging reaches far beyond the physical realm – it’s a gateway to customer connection and brand distinction. As you embark on this packaging journey, remember that every detail matters, and your choice can reshape perceptions and drive success. Will you let your packaging speak volumes about your dedication to quality and aesthetics? The power to captivate and enthrall awaits your innovative touch. Begin shaping a new chapter of packaging excellence and customer delight today! Contact us to start this journey of packaging excellence.



How do custom bubble mailers provide cushioning and protection for items?

Custom bubble mailers have gained popularity as a packaging option due to their ability to withstand the harsh realities of shipping. Whether it is to cushion fragile items or to protect goods during transit, these envelopes are a reliable solution. Their unique structure allows for improved protection, and their customizability with logos or branding can help businesses maintain a professional image.

Custom bubble mailers, regardless of size, are a reliable and practical option for anyone seeking assurance during the shipping process.

Custom bubble mailers provide cushioning and protection for items through their structure and materials. The bubble layer absorbs impacts, disperses pressure, and offers a soft surface to safeguard items during transit. The outer layer protects against scratches, abrasion, and provides waterproof and moisture-resistant properties. Bubble mailers play a crucial role in ensuring the safe delivery of items by mitigating the risks associated with shipping.

custom bubble mailers

Custom bubble mailers consist of two main layers: an outer layer and a bubble layer.

The outer layer is made of durable and tear-resistant materials. It provides a protective barrier against external impacts and pressure.

As indicated by the materials of the film, bubble mailers come in a multitude of varieties, including kraft bubble mailers, co-extruded bubble mailers (poly bubble mailers), pearlescent bubble mailers, and metallic bubble mailers, which can be upgraded to laser bubble mailers by incorporating specialized procedures.

The bubble layer is the crucial component of bubble mailers. It is manufactured using high-pressure polyethylene along with whitening agents and other additives under heat conditions of up to 230 degrees. These lightweight and transparent bubbles provide several advantages, such as moisture-proofing and effectively buffering the goods inside, protecting them from shocks or damages during the shipping process.

A typical bubble in the bubble layer of a bubble mailer has a diameter ranging from 6 to 10 mm and a height of 2 to 3 mm. The taller the bubble, the more effective it is at absorbing impacts during handling, providing enhanced shock absorption capabilities.

The design of the bubble layer provides effective cushioning for items during transit. The arrangement of small bubbles helps absorb and distribute external impacts, preventing direct vibrations and shocks from reaching the enclosed items.

custom bubble mailers

The bubble layer acts as a barrier, isolating vibrations and impacts by absorbing and dispersing external forces, minimizing their impact on the items inside.

The multitude of bubbles creates a uniform distribution of pressure, reducing the concentration of pressure on specific areas. This ensures that the items receive balanced protection throughout the shipping process.

The soft and flexible surface of the bubble layer gently envelops the items, providing a protective cushion and minimizing direct contact with rough surfaces. This helps to prevent scratches and other damage during handling and transportation.

Custom bubble mailers offer comprehensive protection against various risks encountered during shipping.

The outer layer of the mailer is specifically designed to resist scratching and withstand abrasion. It acts as a robust shield, providing a protective barrier against external objects that could potentially damage the items.

The use of plastic materials in the outer layer grants bubble mailers excellent waterproof and moisture-resistant properties. This effectively prevents liquids from seeping into the mailer, safeguarding the items from potential water-related damage.

custom bubble mailers

Customized bubble mailers are versatile and can accommodate a wide range of items for shipping. They provide cushioning and protection, making them suitable for various products. Small electronics, such as smartphones, tablets, and accessories, can be securely shipped using bubble mailers. Delicate jewelry items like necklaces, bracelets, and earrings benefit from the cushioning provided by bubble mailers. Cosmetics, beauty products, and small fashion accessories can also be safely transported using these mailers.

Additionally, bubble mailers are ideal for shipping small home decor items, crafts, art supplies, books, stationery, toys, and collectibles. Fragile items like glassware and ceramics can be protected during shipping with the help of bubble mailers. They are also useful for shipping small parts and components. By selecting the appropriate size, custom bubble mailers ensure a proper fit and optimum protection for the items being shipped.

The variation in texture between bumpy and smooth bubble mailers can be attributed to their manufacturing technique. Foaming is employed in the production of bumpy bubble mailers, whereas smooth ones do not undergo this process. Foaming imparts enhanced shock resistance and visual appeal to the bubble mailers, albeit at a relatively higher cost.

However, it is not advisable to utilize foaming for manufacturing bubble mailers using aluminum foil film and laser film weighing less than 160g, or co-extruded film weighing below 85g. This is because it may result in a compromised aesthetic appearance and the formation of bubbles within bubbles. Moreover, it could lead to inadequate lamination between the film and air bubbles, potentially causing air leakage.

The cost of custom bubble mailers can be calculated based on several factors. While the exact pricing may vary depending on the supplier and specific customization options, here are some common factors that can influence the cost:

Size and dimensions: The size of the custom bubble mailer will impact the amount of material required and the production costs. Larger mailers generally require more materials, resulting in higher costs.

Material and quality: Prices can vary according to different materials. And higher quality materials often offer better protection but may come at a higher cost.

Customization options: If you choose additional customization options, such as printed logos, colors, or special designs, the cost may increase.

Order quantity: The quantity of custom bubble mailers ordered can affect the cost. Ordering in larger quantities may lead to volume discounts or reduced unit costs compared to smaller orders.

To obtain an accurate cost estimate for your personalized bubble mailer bags, simply visit our website, where you can swiftly calculate the bubble mailer price.

custom bubble mailers

As a startup, it can be challenging to navigate the logistics of ordering packaging supplies, especially when it comes to reaching the minimum order quantity (MOQ) set by suppliers.

Fortunately, at Package N’ Go, we understand this concern and offer the lowest MOQ in the industry for custom bubble mailers. With a minimum order quantity of just 5000 pieces, you can customize your packaging to make your brand stand out while keeping costs low. Don’t let minimum order quantity deter you from investing in professional packaging for your products. Contact us at Package N’ Go to learn more about our custom bubble mailers and MOQ options.

Bubble mailers are designed to withstand multiple uses. Many bubble mailers feature double self-sealing strips and tear lines, allowing for easy opening and resealing. By reusing bubble mailers, you can save on packaging costs and minimize waste, promoting cost-effectiveness and sustainability.

While not all recycling programs accept bubble mailers, they can still be recycled through specialized recycling collection facilities. To determine whether your local recycling program accepts bubble mailers, consult the recycling guidelines or reach out to recycling centers in your area. Before recycling bubble mailers, remember to remove any non-recyclable elements, such as plastic or paper labels.

By reusing bubble mailers and recycling them appropriately, you actively contribute to waste reduction and support sustainable practices. It is crucial to follow your local recycling guidelines for the correct disposal of bubble mailers.

At Package N’ Go, we prioritize the significance of delivering tailor-made packaging solutions that perfectly align with our clients’ specific needs. Our extensive range of offerings includes custom poly mailers, custom mailer boxes, custom bubble mailers, tear-open boxes, and more. Regardless of your requirements, we possess the ideal solution to cater to your packaging needs. By partnering with us, you can elevate your business’s packaging to new heights.

Our dedicated team excels in providing unique designs and specialized packaging solutions that will revolutionize your packaging approach. Don’t hesitate any longer. Contact us today and allow our experts to assist you in taking your packaging to the next level.

How to Choose The Right Bubble Mailer For Your Shipping Needs

Nothing is more important when mailing products than making sure they are safe throughout transportation. Achieving that goal can be greatly aided by selecting the proper type of bubble mailer.


In this post, we hope to provide you with a thorough guide to help you choose the best bubble mailer for your unique needs. We’ll also delve into the advantages of different types of bubble mailers and their application scenarios.


What is a bubble mailer?


A bubble mailer, also known as a bubble envelope or padded envelope, is a packaging material designed to protect your shipped or mailed items. Its construction ensures that your contents remain safe and sound during transit, thanks to its cushioning effects.



The main feature of a bubble mailer is the bubble wrap lining on the inside. Bubble wrap consists of rows of small air-filled bubbles trapped between two layers of film. This design creates a protective layer that absorbs shocks and impacts, helping to prevent damage to the items inside.


Discover a variety of sizes and styles available for custom bubble mailers to guarantee your items are properly protected. These mailers come equipped with either a self-sealing adhesive strip or peel-and-seal closure, making packaging a hassle-free process. Eliminate the need for extra tape and glue with our convenient and secure mailers.


Bubble mailers are a top choice for shipping and mailing items due to their lightweight, protective, and convenient features. They offer an extra layer of cushioning that helps guarantee the contents of the envelope arrive at their destination in great condition.


What kinds of items can be shipped with bubble mailers?


Bubble mailers are suitable for shipping a wide range of items, particularly lightweight or moderately fragile ones. Here let’s see some examples of items that can be shipped using bubble mailers:




Bubble mailers provide a protective cushioning layer for important documents such as contracts, legal papers, certificates, or academic transcripts.





Bubble mailers help safeguard printed photographs, ensuring they remain in pristine condition during transit.


Small electronic devices:


Items like smartphones, tablets, digital cameras, or electronic accessories can be securely shipped in bubble mailers. They can be protected from scratches and minor impacts.




Bubble mailers provide a safe and cushioned environment for shipping delicate jewelry items such as earrings, necklaces, bracelets, or rings, etc.



Clothing accessories:


Items like scarves, belts, gloves, or small fashion accessories can be shipped in bubble mailers, offering protection from damage and ensuring they arrive in good condition.


Small media: Bubble mailers are commonly used for shipping CDs, DVDs, or other small media items, protecting them from scratches and ensuring they are delivered without any damage.


Beauty and cosmetic products:


Bubble mailers can be used for shipping small-sized beauty or cosmetic products, including makeup items, skincare products, or sample-sized items.


Crafts and small handmade items:


Bubble mailers provide a cushioned and protective layer for shipping small crafts, handmade products, or DIY items.


Books or magazines: Bubble mailers offer lightweight protection for shipping books, magazines, or other printed materials.


Small toys or collectibles:


Small toys, action figures, trading cards, or collectible items are also good to be shipped in bubble envelopes. They will reach their destination in good condition.


While bubble mailers provide some protection, it’s essential to consider their limitations when shipping delicate, bulky, or heavy items. In such cases, it is recommended to explore alternative packaging options or supplement the bubble mailer with additional cushioning and protective materials.



Things to consider when choosing the right bubble mailer


Bubble mailer sizes


Begin by accurately measuring the length, width, and height of your shipment, including any protruding parts or extra features. Note the largest measurement.


For optimal protection of your item during shipping, it’s crucial to include an appropriate margin. We recommend adding 1-2 inches (2.5-5cm) to each dimension of the item size to ensure it fits comfortably within the bubble wrap and is thoroughly safeguarded.


Alongside its size, the shape of the item plays a significant role in determining the ideal bubble wrap size. For instance, if your item is flat, opting for a larger bubble wrap size ensures that it is well-cushioned and fits entirely for maximum protection.



The thickness of the bubble mailer


-The thickness of the out-layer film


A thicker film provides better durability and tear resistance for items that require a higher level of protection. The thinner film is lighter and is suitable for lightweight items or weight-sensitive applications.

-The thickness of the bubbles (gram weight)


The thickness of the bubble layer is usually expressed using gram weight, which is the weight per square meter. The higher the gram weight, the thicker the bubble layer and the better the cushioning provided. Generally speaking, for fragile or easily damaged items, choosing a thicker bubble layer will provide better protection. For stronger items, a thinner layer of bubbles may be sufficient.


Achieving a perfect match between film thickness and bubble layer weight is crucial to avoid air leakage in bubble bags. If the film is too thick and the bubble layer is too light, the bubbles won’t provide enough support, increasing the chances of air leaks. If you don’t know how to choose, our staff at Package N’ Go will provide you with professional advice.

Item weight and shape


The weight and shape of the object being shipped should be taken into consideration while choosing the best bubble mailer. The bubble layer can be more easily damaged or punctured by heavier objects or objects with sharp edges.


In such cases, it is advisable to use bubble bags with a thicker film and a stronger bubble layer. A thicker film provides increased durability and resistance to punctures, while a stronger bubble layer offers better cushioning and protection against impacts.


Transportation and storage conditions


It is advised to use a thicker layer of film and bubble when traveling or storing objects for prolonged periods of time or in tough environments to enhance safety and protection.


Long-distance transportation or exposure to harsh conditions can increase the risks of impacts, vibrations, and other potential hazards that can compromise the integrity of the packaging. By using a thicker film and bubble layer, you provide an extra layer of protection against such risks.


The thicker film offers improved resistance to tears, punctures, and abrasions, making it more reliable in demanding conditions. Additionally, a thicker bubble layer provides enhanced cushioning, absorbing shocks and vibrations that may occur during transportation or storage.


What are the materials of bubble mailers?


Co-extruded film bubble mailers


The co-extruded film is a specialized plastic film produced through a simultaneous extrusion process involving multiple layers of molten plastic. This process merges two or more plastic materials into a single, multi-layered film through a specially designed die. The result is a continuous film with distinct layers created through the merging of different molten plastic materials.


Co-extruded film bubble mailers are essential for businesses that require mailing solutions capable of providing the right level of protection for various items. These bags are designed with a unique process and structure that delivers both durability and tear resistance, making them the preferred choice for businesses that require a cost-effective solution.


Apart from their lightweight and cushioning abilities, these bubble bags offer waterproof properties, which ensures that items remain protected from external factors. Whether you are looking to protect lightweight or bulky items, co-extruded film bubble bags are versatile alternatives that never disappoint.


Pearlescent bubble mailers



The pearlescent film is composed of polypropylene resin, calcium carbonate, pearlescent pigment, and other additives. These components are mixed together and then stretched in both directions. The resulting film exhibits several features: a milky white appearance, a pearlescent effect, excellent tensile strength, effective shading, moderate density, and stability. It offers high stiffness, low static electricity, high gloss, high whiteness, good pearlescent color, and performs well in printing compounds.


Pearlescent bubble mailers are becoming increasingly popular in the shipping industry. These mailers offer both a functional and aesthetically pleasing solution for shipping products. They are sturdy and durable, providing extra protection to their contents during transit while their eye-catching, pearlescent finish gives a professional touch to any package.


Pearlescent bubble mailers offer exceptional durability and an impressive aesthetic appeal. Moreover, these mailers are light in weight and easy to utilize. They prove to be a trustworthy and cost-effective option whether you are shipping fragile and delicate items or seeking an attractive touch to your packaging.



In fact, there are considerable visual similarities between the co-extruded film and pearlescent film, making it challenging to tell them apart at first glance.


One of the ways to differentiate between co-extruded film and pearlescent film is by checking if there is color difference between the inner and outer layers. In the co-extruded film, the inner and outer layers typically usually have different colors, while pearlescent film maintains a consistent color throughout.


Another distinguishing factor is the elasticity of the film. The co-extruded film tends to be more elastic, allowing for flexibility and stretching, whereas pearlescent film is relatively inelastic and can be easily peeled off.


The co-extruded film frequently releases an unpleasant smell when burned, but the pearlescent film doesn’t smell at all or could even have a faint perfume.


The co-extruded film can be produced using a blend of recycled materials, making it more environmentally friendly. In contrast, the pearlescent film typically lacks recycled content in its manufacturing process.


Overall, by considering the color difference, elasticity, burning odor, and use of recycled materials, we can effectively distinguish between co-extruded film and pearlescent film.


Kraft bubble mailers


Kraft paper is a type of paper that is produced from the chemical pulping of wood pulp, specifically from softwood trees like pine or spruce. It is known for its strength and durability.


Kraft paper, derived from the German word for strength, is produced using the kraft process. This method treats wood chips with chemicals like sodium hydroxide and sodium sulfide to transform them into fibers. This process removes the lignin, a natural polymer that gives wood its rigidity but makes paper weak and prone to yellowing over time.


The resulting pulp is then pressed and dried to form kraft paper. It has a relatively high tensile strength and tear resistance, making it suitable for various applications that require robust packaging or wrapping materials.


Kraft bubble envelopes have rapidly gained popularity in the shipping and packaging industry due to their impressive durability and tear resistance. The combination of a robust outer layer made of kraft paper and a protective inner layer of bubble film ensures that items packaged within these envelopes are effectively shielded from potential damage and wear.


Beyond providing essential protection, these envelopes offer a range of practical benefits. They are lightweight and flexible, facilitating easy handling and storage. Moreover, their eco-friendly materials make them a sustainable option, as kraft paper can be recycled and reused. Overall, kraft bubble envelopes provide a reliable and responsible solution for safely shipping valuable and delicate items.


It is worth noting that among various materials used for bubble bags, kraft bubble bags have a significant feature: they can be written on directly.


Metallic bubble mailers



A unique variety of bubble mailers is the metallic bubble mailer. Metallic bubble bags are the best option for people looking for a luxury presentation and great quality. These bags’ precisely engineered construction not only ensures that your expensive goods are shielded from light, heat, and gas, but also blocks the entry of any moisture, oxygen, or other potentially harmful components.


Thanks to their exceptional strength and durability, these bags can withstand significant external pressure and impacts, while their lightweight and flexible nature makes them effortless to carry, pack and store. The metallic texture of these bags adds to their professional, luxurious appeal, making them an ideal choice for a variety of high-end products.


There are mainly two kinds of metallic bubble mailers: aluminized bubble mailers and aluminum foil bubble mailers. To quickly distinguish between aluminum foil and aluminized film, there are several key differences to consider.


Firstly, aluminum foil film appears silvery white or silvery gray, while the aluminized film has a silvery yellow or silvery black appearance with higher brightness.


Secondly, aluminum foil film feels thicker, stiffer, and heavier compared to the lighter and softer feel of the aluminized film.


Lastly, when folded, aluminum foil film retains fold marks, while aluminum packaging quickly springs back without leaving any noticeable fold marks.


Hard shell bubble mailers and soft shell bubble mailers


The manufacturing technique used in bubble mailers plays a significant role in their appearance and performance. One key technique is “foaming,” which creates a bumpy texture on the surface of the mailer, and this mailer is called hard shell bubble mailer. However, not all bubble mailers undergo this foaming process.


Foaming bubble mailers offer several advantages, including enhanced shock resistance and improved visual appeal. The foaming process results in a rough texture that gives an additional layer of cushioning, improving protection for the mailer’s contents. It’s crucial to keep in mind, though, that hard shell bubble mailers often cost more than soft shell bubble mailers.


It is generally not recommended to produce hard shell bubble mailers using certain types of films. For instance, aluminum foil films and laser films with a weight below 160g, or co-extruded films below 85g, may not be suitable for the foaming process. This is because using these films in hard shell bubble mailers can result in a lack of aesthetics and the formation of “bubbles within bubbles”. Moreover, there is a risk of poor lamination between the film layers and air bubbles, which can lead to air leakage issues.


It’s crucial to select the appropriate technique based on the specific characteristics of the film being used to ensure the integrity and functionality of the bubble mailer.





In summary, when selecting the right bubble mailer, factors to consider include the size and shape of the mailer, the thickness of the film and bubble layer, the weight and shape of the item being shipped, transportation and storage conditions, and the specific materials used for the bubble mailer. Different materials like co-extruded film, pearlescent film, kraft paper, and metallic options offer unique features and advantages, such as durability, tear resistance, waterproof properties, and professional appeal. Additionally, the foaming technique in bubble mailer manufacturing can provide enhanced shock resistance and visual appeal.


Looking for bespoke packaging solutions for your business? Package N’ Go has got you covered! We offer a minimum order quantity (MOQ) of 5000 pieces for all kinds of mailer bags, catering to businesses of any size, whether you’re a small start-up or an established corporation.


Our skilled staff makes certain that the products are of the highest quality and both secure your goods during shipping and effectively convey the essence of your company. Because we value professionalism and meticulousness, our individualized bubble mailers are the ideal packing solution for you. Start your journey with us today and experience the convenience and reliability of our custom packaging solutions.

What is a Recycled Poly Mailer And Why Should we Use it?

With e-commerce and online shopping rapidly gaining momentum, custom mailer bags have emerged as a convenient and viable solution. Though, with the mounting packing waste and demand for raw materials, the environmental implications must be addressed.

Massive quantities of plastic waste pollute our oceans, kill species, and exacerbate the global climate disaster every day.

According to incomplete statistics, the global average of each person will produce about 20 kg of plastic packaging waste per year.

That’s where recycling polyethylene mailers comes in as an important solution. By reusing these materials, we can reduce our impact on the environment and promote sustainability.

A recycled poly mailer is meticulously fashioned using reclaimed polyethylene plastic, a remarkably adaptable and pliable substance renowned for its lightweight attributes. This eco-friendly mailer option exemplifies a commitment to sustainability, as it helps reduce the demand for new plastic production while repurposing existing materials, all without compromising on its flexible and resilient qualities.

Recycled poly mailers

The use of recycled polyethylene mailers offers several significant environmental benefits. Firstly, it helps to conserve resources by reducing the need for new raw materials. Manufacturing traditional plastic bags typically involves extensive use of petroleum and chemical raw materials, while recycled polyethylene mailers minimize this dependence and conserve energy and water resources.

Secondly, the production of recycled mailers results in fewer greenhouse gas emissions and less air pollution compared to the manufacturing of new plastic products. By diverting waste materials from landfills and reprocessing them into useful mailers, the overall environmental impact is reduced.

Finally, using recycled polyethylene mailers supports the idea of a circular economy, which encourages the recycling and reuse of resources rather than their disposal as waste. Promoting the usage of recycled materials helps to produce a more sustainable and ecologically friendly approach to packing and mailing operations by reducing the accumulation of plastic waste.

Adopting recycled poly mailers can help enhance a company’s brand image. Consumers are increasingly seeking out brands that align with their values, including sustainability and environmental consciousness. Using recycled materials allows businesses to position themselves as forward-thinking and socially conscious, appealing to a rising market of consumers who care about the environment.

In some regions, there are regulations and policies in place that encourage or require the use of recycled materials in packaging. By using recycled poly mailers, companies can ensure compliance with these regulations, avoiding any potential penalties or legal issues.

The processing of making recycled poly mailers involves several steps to transform post-consumer or post-industrial plastic waste into new packaging materials.


Collection and sorting


The first step involves collecting post-consumer plastic materials, such as used plastic bottles and containers. These plastics are then sorted to separate different types of plastics and remove any contaminants.


Cleaning and shredding


The sorted plastic materials undergo a thorough cleaning process to remove dirt, labels, and other impurities. After cleaning, the plastic is shredded into small pieces, often referred to as plastic flakes or granules.


Melting and extrusion


The shredded plastic flakes are melted down using heat, typically in an extruder. An extruder is a machine that melts the plastic and forms it into a consistent molten mass.


Filtration and pelletizing


During the melting process, any remaining impurities are filtered out, ensuring the quality of the molten plastic. The molten plastic is then cooled and solidified into small pellets or beads.


Mixing and formulation


Depending on the specific requirements of the recycled poly mailer, additives may be mixed with the plastic pellets. These additives can include colorants, stabilizers, and other materials to enhance the properties of the plastic.


After undergoing the aforementioned treatment, the recycled poly mailer material can be used in the production process, which is the same as that of new material. The production process typically involves film blowing, printing, bag making, and other relevant steps.


Film blowing


The recycled polyethylene material is melted and extruded through a film blowing machine. This machine stretches and forms the molten material into a continuous tube-shaped film. The film is then cooled and solidified as it passes through a series of rollers.




The produced polyethylene film can be subjected to printing processes to add branding, logos, or other desired designs.


Bag making


Once the polyethylene film is printed, it can be cut and sealed to create individual poly mailer bags. Bag making machines are used to cut the film into specific dimensions, fold it, and seal the edges to form the bags. Additional features such as adhesive strips or perforations may also be added during the bag-making process.

Poly mailers made of new materials and recycled materials can have similar performance and quality characteristics. However, there may be slight differences in color and stretching force due to variations in the recycling process and the properties of the recycled polyethylene.

In addition, poly mailers made from recycled materials are more cost-effective compared to those made from new materials.

According to laws, regulations, and the requirements of businesses, it is possible to incorporate a certain percentage of recycled materials into new materials by blending them. For example, a specific percentage of recycled materials, such as 30% or 50%, can be added to the new materials during the production of poly mailers.

This approach allows for a balance between utilizing new materials and incorporating recycled materials, promoting sustainability while maintaining the necessary performance and quality standards.

Recycled poly mailers

Amazon: As part of “No Single-Use Plastic” drive, Amazon has now opted for recycled polyethylene mailers to pack products during delivery. This move marks a significant step towards more sustainable packaging and reducing environmental imprint. Let’s join the effort, and opt for sustainable choices today.

Patagonia: Patagonia, an outdoor apparel and gear brand, is widely recognized for its environmental consciousness. They have implemented the use of recycled polyethylene mailers as shipping packaging for their products. These mailers are made from recycled polyethylene material, emphasizing their commitment to reducing waste and promoting circularity in their packaging practices.

IKEA: As a leader in home furnishings, IKEA is committed to sustainability. To reduce plastic waste and promote resource responsibility, the company has incorporated recycled polyethylene mailers into their packaging. This strategy is exactly in line with IKEA’s sustainability objectives.

Adidas: Placing a strong emphasis on sustainability and environmental protection, Adidas has integrated recycled polyethylene mailers into their packaging solutions for selected products. By utilizing recycled materials, Adidas reduces the environmental impact associated with the production and disposal of packaging materials, thereby promoting a more sustainable approach to its operations.

The practical use of recycled polyethylene mailers still presents a few challenges despite their many benefits. The ability to properly reprocess recycled materials as well as their availability present one of the main supply chain concerns. To encourage the broad use of recycled polyethylene pouches, a strong supply chain system must be established, as well as strategic alliances.

Moreover, customer awareness and education are crucial. It is crucial to inform the public of the advantages of recycled polyethylene mailers and to emphasize their favorable effects on the environment. By increasing awareness, consumers may choose ecologically friendly packaging solutions and make informed decisions.

Furthermore, institutional support and policy incentives from governments and relevant authorities are instrumental in driving the adoption of recycled polyethylene mailers. Governments can implement regulations and incentives that encourage businesses to prioritize the use of recycled materials and support the development of recycling infrastructure. This can create a favorable environment for the integration of recycled polyethylene mailers into mainstream packaging practices.


To elevate the use of recycled polyethylene mailers, it is essential to work in collaboration with the stakeholders across the supply chain, which include manufacturers, recycling facilities, government bodies, and consumers. By collectively tackling these challenges, we can propel the practical implementation of recycled polyethylene mailers to improve the sustainability and environmental consciousness of the packaging industry.


As environmental sustainability gains more attention, businesses must take accountability and make conscious decisions. For e-commerce companies seeking an eco-friendly packaging option, recycled polyethylene mailers are an excellent solution.

Package N’ Go is your one-stop shop for custom packaging solutions. If you’re looking for eco-friendly products and interested in utilizing recycled poly mailers, recyclable poly mailers, or returnable poly mailers in your business, Package N’ Go is perfect for you! Reach out to us and explore our sustainable packaging world. Let’s work together to promote a cleaner and more sustainable future.

How do Poly Mailers With Logo Benefit Your Business?

As e-commerce continues to dominate the market, poly mailers have become the packaging preference for many businesses, as they are a great option for mailing a variety of products because of their lightweight, strong, and customizable features.


Making your brand stand out might be challenging when there are so many packages flying around. Actually, there are many original ways to use this conventional packaging choice to enhance your brand. You can transform your poly mailers into a potent marketing tool that will make you stand out in the sea of shipments by taking the time to think about the distinctive personality of your business.


Imagine getting a package in the mail and, as you pick it up, being able to tell right away what brand it is because of the distinctive and striking logo printed on the mailer bag. This situation serves as an example of how successful employing a poly mailer with your brand printed on it can be.

Poly Mailers With Logo Benefit

Logo poly mailers have various benefits for the business including improving brand recognition, enhancing consumer curiosity, breaking the language barrier, increasing professionalism, and being more imaginative than the brand name.

Without a doubt, logo printing on poly mailers has a significant impact on creating connotative thoughts and leaving enduring impressions. Beyond only being visually appealing, a small design like this one has a big impact on how well people remember the company. The logo and design stand out more than the textual explanations, which helps customers remember and recognize them. Customers develop a strong association between the brand name and logo as a result of this subtle but significant link, which enhances their interactions and relationships with the trusted brand.

This logo is more than just a picture of the company. It conveys individuality and captures people’s interest, piquing their curiosity about the meaning behind it. As the recipient, the sparked interest heightens the anticipation of opening the bag and creates a strong emotional bond with the company. This straightforward yet effective strategy shows how cutting-edge branding techniques, such as creating a distinctive logo printed on a poly mailer, may attract consumers’ interest, thereby increasing the entire brand image and customer experience.

Language barriers often make it difficult to accurately communicate a product’s message when selling it in different countries. An instantly recognizable and widely appealing logo can serve as a bridge in these situations, bridging linguistic barriers and guaranteeing that the product’s primary message is communicated to a wide audience. A well-designed logo is undoubtedly an essential component of any effective marketing effort.

The printed logo gives a professional and polished look to the packaging. It demonstrates that you take your business seriously and you are proud of your brand. You are committed to providing qualified products and services.

Poly Mailers With Logo Benefit

In addition to being an effective marketing tool, a printed brand on a mailer bag offers businesses a unique opportunity to demonstrate their creativity and originality. A well-designed logo, unlike a simple business name, uses a range of shapes, colors, and patterns to give clients a striking visual experience. This enables them to connect the brand with a greater variety of interesting and significant imagination. Brands may successfully communicate their fundamental values and message by creating an imaginative and intelligent logo, leading to a stronger bond between customers and the goods they stand for.

Poly mailer takes gravure printing, which is one of the four main printing methods. The ink from the intaglio pit is directly imprinted on the substrate. The amount of ink used to make the printed picture depends on the size and depth of the intaglio pit. A deeper hole holds more ink and will leave a thicker layer of ink on the substrate, whereas a shallower pit holds less ink and will leave a thinner layer of ink there.

The intaglio printing plate is made up of the plate’s surface and the pit that matches the original text. When printing, ink is poured into the pit, and ink on the surface of the printing plate is scraped off using an ink scraper, and then a specific amount of pressure contact takes place between the printing plate and the substrate, transferring the ink in the pit to the substrate and concluding the printing process. In this way, you get your logo and design on the bag.

The cost-effectiveness of poly mailers is a big plus for companies trying to up their packaging game without going broke. The final cost will not increase significantly if you choose a printed design.

If it is only a single-color logo, the additional cost is almost insignificant. Averagely, printing a logo on one mailer bag only cost 0.01 US dollars. While it is true that using various colors may raise the price, altogether, the printing component only accounts for a very small portion of the overall cost of making a poly mailer. A personalized and eye-catching poly mailer offers advantages that well outweigh the small cost increase.

A poly mailer with logo provides businesses and customers with enormous value for only a small portion of the cost increase. Businesses may make a big impact, stand out from the crowd, and strengthen brand identification by investing in eye-catching and improved poly mailers while still staying within the budget.

Poly Mailers With Logo Benefit

You might wish to look at some effective examples of branded poly mailers. Some well-known companies utilize poly mailers imprinted with their logos as a way to strengthen their identity and give their customers a special unboxing experience. The following well-known companies employ poly mailers with their logos: Amazon, Nike, Adidas, Zara, ASOS, and a lot more.

As part of its branding strategy, Nike, like many other companies, prints the brand logo on the poly mailer. Because it is frequently the first thing a consumer sees after receiving a delivery, the poly mailer is a crucial touchpoint in the customer experience. Nike is able to strengthen its brand identification and give its clients a memorable unboxing experience by printing its logo on a poly envelope.

Printing the Nike logo on the poly mailer not only helps to increase brand recognition, but also serves to discourage counterfeiters. Nike is able to convey to its customers that the product inside is authentic and originates from a reliable source by using a branded poly mailer, as counterfeiters frequently utilize plain, unbranded poly mailers to transport their phony products.

It is crucial to pick a high-quality poly mailer to print your logo on. Inferior mailer envelopes may rip or tear during delivery, harming both your product and the reputation of your company.

Your company’s logo should be placed strategically on the poly mailer. It must be prominently put and exhibited so that customers may see it and recognize it right away. The size of your logo and the envelope should be taken into consideration when deciding where anything should fit.

Your logo’s dimensions and color should be carefully examined. The logo should be visible and not overly huge such that it detracts from the package as a whole. To make sure the logo shines out against the color of the poly mailer, the logo’s color should be carefully picked.

Poly Mailers With Logo Benefit

If you don’t want your design to be only a logo and want something more intricate, here are some tips for you. One is that the pattern better not go all the way to the bottom border on the front and rear sides, or to the left and right edges. Also, staying away from using too many colors reduces the risk of inaccurate/inferior overprinting. Last but not least, it is advisable to avoid including decorations in the sticky area in order to prevent the design from being covered after sealing. All of these details may seem minor, but they have a major impact on the final look of the bag after production.

Use a distinctive logo mailing bag to promote your company and make a statement. Your hunt ends with Package N’ Go as your provider. You may design a mailing bag that is genuinely one-of-a-kind with our extensive range of sizes, materials, and customization options. Get a unique mailer bag from Package N’ Go to set yourself out from the competition and win over your consumers. Get in touch with us right away!

Cold or Hot? Exploring the Benefits of Foil Stamping

Are you looking to add an extra touch of luxury to your product packaging? Have you considered foil stamping as a potential option? Foil stamping is a popular choice for businesses due to its ability to add depth and texture to packaging designs. But what type of foil should you choose, cold or hot? Let’s break down the differences between cold vs hot foil stamping.

Foil stamping is a printing process that uses heat, pressure, and a metallic or pigmented foil to create a shiny, metallic or colored design on paper or other materials. The process involves a metal die, which is heated and pressed onto the foil, transferring the foil’s color and design onto the surface of the material. Foil stamping is commonly used in the production of high-end packaging, invitations, and other printed materials to add a luxurious, eye-catching effect.

Metallic foil stamping is the most traditional form of foil stamping and is often used to create a luxurious and high-end look. The foil comes in a variety of metallic shades such as gold, silver, copper, and bronze, and can be combined with embossing to create a three-dimensional effect.

Pigment foil stamping involves using opaque pigments to create a more vivid and colorful appearance. It is often used to create bold designs on darker substrates or to match specific brand colors.

Cold vs Hot Foil Stamping

Holographic foil stamping is a newer form of foil stamping that creates a shimmering and iridescent effect. The foil reflects light at different angles, creating a dynamic visual effect that is perfect for creating eye-catching designs.

Both hot foil stamping and cold foil stamping can be used to create these three types of foil stamping effects. Hot foil stamping involves using heat and pressure to transfer the foil onto the packaging substrate, while cold foil stamping uses a special adhesive to apply the foil. The choice of hot or cold foil stamping depends on the packaging substrate and the desired design effect.

When it comes to the manufacturing process, cold vs hot foil stamping are distinctly different. The method used for each process has a significant impact on their productivity. The differences in production methods between the two techniques account for their varied levels of efficiency.

Hot foil stamping involves directly electroplating aluminum onto a heated plate, which is then layered onto the surface of the material to be stamped. This process requires a high level of precision, as the temperature and pressure of the stamping machine must be carefully controlled to ensure a crisp, clear image.

Hot foil stamping is a relatively fast process, with typical production speeds of several hundred sheets per hour. We have state-of-the-art machines that can achieve hot foil stamping production speeds of up to 3000-4000 sheets per hour.

On the other hand, cold foil stamping involves applying a layer of adhesive to the surface of the material to be stamped, followed by a layer of metallic foil. The foil is then transferred to the material using a special UV curing process, which solidifies the adhesive and bonds the foil to the surface.

This process takes longer than hot foil stamping, as the adhesive must dry before the foil can be applied. Cold foil stamping is typically slower than hot foil stamping, with production speeds ranging from several dozen to several hundred sheets per hour, depending on the specific equipment and process used. Our cutting-edge equipment allows us to achieve production speeds of 2500-3000 sheets per hour for cold foil stamping.

Foil Stamping

Hot foil stamping is typically used for areas like logos, text, or simple designs. The process allows for precise and high-quality results, making it a popular choice for luxury packaging, high-end stationery, and promotional materials. However, due to the limitations of the stamping process, hot foil stamping may not be suitable for intricate or detailed designs.

Cold vs Hot Foil Stamping

In contrast, cold foil stamping can be used for both fine details, such as thin lines and outlines, as well as larger areas. This makes it a versatile choice for a variety of applications, including packaging, labels, and promotional materials. However, the cost of cold foil stamping is typically higher than hot foil stamping, making it less practical for smaller runs or projects with a limited budget.

Hot foil stamping provides greater versatility during production as compared to cold foil stamping. With hot foil stamping, it is possible to create embossed foil labels, as well as to print on a wide range of textured surfaces. As a result of this flexibility, hot foil stamping is particularly well-suited for the production of cards and invitations. Conversely, cold foil stamping is limited in its application, as it can only be applied to completely smooth surfaces.

Foil stamping can be combined with other post-press techniques to create even more intricate and visually stunning designs. Some commonly used post-press techniques that can be combined with foil stamping include embossing, debossing, die-cutting, and spot UV coating. By combining these techniques with foil stamping, a wide range of textures, shapes, and effects can be achieved, resulting in highly personalized and premium-looking packaging products.

Cold vs Hot Foil Stamping

One of the most common techniques used in combination with foil stamping is embossing. Embossing adds a three-dimensional texture to the design by raising certain areas of the substrate. When combined with foil stamping, the raised areas create a striking contrast against the foil, making the design stand out even more. This combination is often used to create high-end packaging products such as luxury boxes, business cards, and invitations.

Both hot foil stamping and cold foil stamping can be combined with embossing to achieve this effect. Hot foil stamping is especially suitable for combining with embossing, as the heat and pressure used in the process help to enhance the three-dimensional effect. Cold foil stamping, on the other hand, may require additional processing steps to achieve the same level of embossing depth.

Hot foil stamping is generally more affordable compared to cold foil stamping. This is because hot foil stamping does not require the use of additional materials, such as adhesives or curing processes. Hot foil stamping simply uses a heated die to transfer the metallic foil onto the desired surface, making it a cost-effective choice for projects with a limited budget.

On the other hand, cold foil stamping is typically more expensive than hot foil stamping due to the additional materials and processes involved. The adhesive used in cold foil stamping can be expensive, and the curing process requires specialized equipment and expertise. Additionally, the metallic foil used in cold foil stamping is often more expensive than that used in hot foil stamping. Despite the higher cost, cold foil stamping offers unique capabilities and versatility, making it a preferred choice for high-end packaging and promotional materials.

Both hot foil stamping and cold foil stamping offer distinct advantages. Hot foil stamping is faster and more affordable, making it a great choice for projects that require quick turnaround times or have a limited budget. On the other hand, cold foil stamping offers greater versatility and precision, allowing for intricate designs and detailed artwork. Both processes are widely used for a variety of applications, including packaging and promotional materials. Whichever process you choose, foil stamping can add an elegant touch to your project.

Overall, hot foil stamping is the ideal choice for projects that require quick turnaround times and have a limited budget. Cold foil stamping provides greater detail and precision, but requires additional materials and processes, making it more expensive. Both processes offer unique benefits, so consider your specific needs before deciding which one is right for you. With the right equipment and expertise, foil stamping can help bring your project to life.

No matter the size of your project or the budget you have available, both hot foil stamping and cold foil stamping can provide a variety of benefits. Hot foil stamping is typically faster and more cost-effective than cold foil stamping, while cold foil stamping offers greater detail and precision.

The right foil stamping solution can help create beautiful and unique results that will make your project stand out from the crowd. With the right equipment and expertise, you can achieve stunning results no matter which process you choose.

If you’re still uncertain about which postpress to pick for your product and design, look no further than our professional team of experts. With us as your go-to packaging supplier, all it takes is a few simple clicks from you – Package N’ Go care of the rest! Don’t let indecision hold up the process; trust in us to make everything run smoothly.