Custom Padded Mailers (Bubble and Kraft)

A custom padded mailer is an envelope-style shipping bag with a cushioning layer inside, printed with your branding on the outside. It is built for light, durable items such as apparel, books, cables, cosmetics in tubes and small accessories that do not need a rigid box. TBPB makes them to your size with no minimum order, and if you bring a written quote for the same specs we will beat it.

What a padded mailer protects against, and what it does not

The padding is a layer of bubble film or a similar cushion inside the envelope wall. It absorbs scuffs and light knocks, and the outer layer keeps dirt and moisture splashes off the contents. It does not resist crushing. A mailer will flatten if a parcel is stacked under weight, so anything that breaks under pressure, such as a glass bottle, a boxed candle or a fragile ceramic, belongs in a corrugated box or one of our custom mailer boxes. The rule of thumb is simple: if it bends harmlessly, a mailer is fine. If it cracks, use a box.

Kraft or bubble exterior, and how to choose

Kraft-exterior padded mailers have a paper outer face, which prints in a natural, understated way and reads as eco-minded to buyers. They take black and dark inks well. Bubble mailers with a poly exterior hold up better against moisture and tearing, and they take bright colour print more cleanly. Pick the exterior based on where your parcels go. A short domestic run in dry weather suits kraft. If parcels may sit on a porch in the rain, a poly face is more forgiving. Ask us what exterior options suit your print.

The closing strip is usually a peel-and-seal adhesive flap. It grips well when the surface is clean and dry and fails when dust or condensation gets on it, so store mailers in a dry place and seal them promptly.

Sizing a mailer for your product

Measure the item at its widest and longest, then add its thickness once packed in a polybag or tissue. The mailer interior should be slightly larger than the item on every side, but not so large that the contents slide around. A mailer that is one size too big wastes material and encourages shifting. One that is too small strains the seal and may burst at the flap. If you are shipping multiple items together, size for the whole stack, not one piece.

• Kraft or poly exterior, with printed logo, pattern or message
• Peel-and-seal adhesive flap
• Custom sizes cut to your product, not only standard dimensions
• One-colour or full-colour print depending on the surface
• Optional inside print or a branded thank-you note card

Packing tips that prevent returns

Put soft goods in a polybag first, so a split in the mailer does not expose them. Press out the air before sealing, since a puffed-up mailer is easier to snag and tear. Leave the adhesive strip uncontaminated by dust, and press along the whole length, not only the middle. For items with sharp corners, such as a hardback book, add a sheet of card inside so the corners do not punch through the lining in transit. These small habits matter more than the mailer spec once volumes grow.

When a box is the better choice

Choose a box if the product is fragile, has a rigid shape, needs retail presentation or will sit in a customer’s hands for a while. The gift mailer boxes and the wider mailer boxes category cover those uses. Padded mailers shine on low weight, but they offer little in unboxing theatre compared with a printed box.

Next step

Send the product dimensions, how many items go in each parcel and the quantity, even if it is a single mailer. We confirm the size and exterior, set up the print and quote it.

Frequently asked questions