Custom Poly Mailers

Custom Poly Mailers from Box Squire offer durable, lightweight packaging that protects your products and promotes your brand. Add your logo, colors and designs to create a consistent customer experience. Order as few as 100 units. Fast turnaround. Affordable, professional packaging for eCommerce businesses and brands of all sizes.
Box Squire’s Custom Poly Mailers protect your products and promote your brand. Order starting at 100 units. Waterproof, tear-resistant, fully customizable. Ideal for eCommerce, retail and direct shipping.

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Custom Poly Mailers for reliable, on-brand shipping

Custom Poly Mailers from Box Squire are a smart way to ship lightweight items while strengthening your brand. These mailers are strong, waterproof and fully customizable, giving your packages a professional look from the moment they arrive.

With low minimums and fast production times, you can start small and scale up as needed. Whether you’re shipping apparel, accessories or subscription products, these mailers get the job done right.

Why Choose Custom Poly Mailers?

Custom mailers do more than hold your product. They communicate the quality of your brand from the first touch.

  • Protect items from dirt, moisture and damage in transit
  • Deliver a branded unboxing experience at a low cost
  • Lightweight to reduce shipping costs
  • Available in multiple sizes for different products

A printed mailer is a small detail with a big impact. It sets expectations before the package is even opened.

Material and Print Quality

Your packaging should reflect the quality of your brand. Box Squire ensures every mailer meets high production standards.

  • Made from durable polyethylene for flexibility and strength
  • Tear-resistant and waterproof to protect contents
  • Full-color printing for clear, vibrant designs
  • Matte or glossy finishes available

Strong material and clean printing help your packages look sharp and arrive intact.

Minimum Order Quantity & Turnaround Time

Start small or go big. Box Squire gives you flexible order options with reliable delivery timelines.

  • Low MOQ starting at 100 units
  • Standard production: 10 to 14 business days
  • Rush production: 8 to 10 business days
  • Orders ship from the USA

You get control over your packaging needs without long wait times or high upfront costs.

Customization Options

Build packaging that reflects your brand. From bold logos to full-color designs, we help you stay on-brand.

  • Upload custom artwork or choose from templates
  • Add logos, slogans, patterns, or QR codes
  • Multiple sizes to fit your products
  • Choose between self-seal or glue strip closure

Custom mailers are an affordable way to improve brand visibility and customer retention.

Use Cases: What to Ship

These mailers are designed for non-fragile, soft, or pre-boxed items. They work across many industries.

  • Apparel like t-shirts, hoodies, leggings and socks
  • Accessories including bags, scarves and hats
  • Subscriptions or flat merchandise
  • Documents or printed material

Poly mailers keep your shipments clean, simple and secure during delivery.

Eco-friendly options are available

Choose sustainability without compromising strength or style.

  • Recyclable polyethylene material
  • Optional biodegradable film on request
  • Reduce packaging waste compared to boxes
  • Lightweight material lowers carbon footprint in transit

Sustainable packaging supports your brand’s environmental goals and appeals to eco-conscious shoppers.

FAQs

What is the minimum order for custom poly mailers?
The minimum order quantity is 100 units.

How long does production take?
Standard turnaround is 10 to 14 business days. Rush production is 8 to 10 business days.

Are these mailers waterproof?
Yes. They are made from waterproof polyethylene to protect your items.

What sizes do you offer?
We offer multiple standard sizes and custom sizing options . Ask for a size guide.

Can I print in full color?
Yes. We support full-color CMYK printing for logos, artwork and detailed designs.

Materials

White Cardboard: SBS (C1S), SBS (C2S), Uncoated Stock, Texture Stock,
Metalized/Pearl Cardstock: Silver, Gold, Holographic.
Brown: Natural Brown Kraft Card Stock
White Front Colored Back: CCNB (Grey Back), CCKB (Kraft Back)
Shipping Boxes: White or Brown Fluted Corrugated Stock
Rigid: Grey-board plus premium paper (Similar to iPhone boxes)

Material Thicknesses

Paper: 80 lbs, 100 lbs, 120 lbs
Cardstock: 12pt, 14, pt, 16pt, 18pt, 24pt, 28pt.
Custom Corrugated Stock: 2-Ply or Single Fluted, 3-Ply or Single Flute with Double sided Card, 4-Ply or Double Fluted Stock.
Rigid: 60pt to 120pt or 2mm to 3.5mm thick

Finishing Types

Lamination: Gloss, Matte, Sandy Matte, Soft Touch
Coating: Varnish Gloss or Matte

Add-Ons

Foiling/Hot Stamping, Spot UV, Flood UV, Embossing, Debossing, Die Cutting window w/PVC

Colors

CMYK, PMS Spot Colors, All Custom

Printing Techniques

Litho/Offset Printing, Digital printing, UV printing, Silk Screen, and more

Inks

Water based, Oil based, and Chemical based

Padding/Inserts

On Cardboard Boxes: Cardstock or corrugated On Rigid Boxes: Soft Foam, EVA Foam, Silk or Velvet lining, Cotton Pillows, and Silk Fabric Pouches

Durability

Yes, our boxes are made of durable materials like cardboard, corrugated fluted board to secure the products inside

Capacity/Breaking Strength

50- 60 pounds (lbs) depending on

Fold & Portability

Cardboard Boxes: Are foldable, space-saving, and portable for easy shipping.
Rigid Boxes: Pre-Assembled, Fully-Assembled Non-foldable

Recyclability

Yes, our boxes are made of sustainable, eco-friendly, and biodegradable materials.

Shipping Mode

Air Cargo through DHL, FedEx, and UPS, Sea Cargo

Turnaround Time

Air Cargo: 10 to 12 working Days.
Sea Cargo: 6 to 8 working weeks.

Materials

White Cardboard: SBS (C1S), SBS (C2S), Uncoated Stock, Texture Stock,
Metalized/Pearl Cardstock: Silver, Gold, Holographic.
Brown: Natural Brown Kraft Card Stock
White Front Colored Back: CCNB (Grey Back), CCKB (Kraft Back)
Shipping Boxes: White or Brown Fluted Corrugated Stock
Rigid: Grey-board plus premium paper (Similar to iPhone boxes)

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