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How to Choose Right Poly Mailer Size and Type

Poly mailers are a great way to send small items through the mail. They are lightweight and easy to use, and they come in a variety of sizes to fit your needs. But how do you know which size to choose? Here is a guide to help you choose the right size poly mailer for your needs.

Poly Mailer Sizes

Poly mailers are a great way to ship items because they are lightweight and waterproof. They come in a variety of sizes, so you can find the perfect fit for your item. The smallest size is typically 9x6 inches and it goes up to 19x24 inches.

When choosing a poly mailer size, you should consider the weight and dimensions of the item you are shipping. If the item is too large or too heavy for a particular size, it will be difficult to send with poly mailers without additional protection. You should also make sure that the mailer is big enough to fit the item comfortably without bending or folding it.

What Poly Mailers to Use

Shipping items can be expensive, so it’s important to choose the right type of mailer to send your product. Poly mailers are a great option because they are durable and provide good protection for your item. You can choose from a variety of colors and designs so you can find the perfect one to match your branding. Poly mailers are also affordable, making them a cost-effective option for shipping.

Here are a few factors to keep in mind when selecting a poly mailer that’s right for your items:

Size: make sure to order a size that allows for comfort and room for your product.

Thickness: depending on the type of product you sell, you may need a heavier-duty poly mailer. Thicker mailers are sturdier and provide more protection for your item, especially if it’s being shipped via UPS or FedEx.

Weight: shipping weights can vary, so it’s important to keep this in mind when selecting a mailer. Also, if you are shipping to an area with specific requirements, you should look into the weight limits for different mailers.

Water resistance/waterproof: in case your item gets wet or exposed to high levels of humidity, poly mailers provide protection against that.

Puncture resistant: You don’t want your items being sent into the abyss of a warehouse storage room because they were punctured by a mailer that couldn’t stand up to the task. Make sure to choose tear-puncture resistant poly mailers.

Aesthetics: There are tons of styles and designs to choose from, so you can find one that fits your brand and aesthetic. There are variety of different designs and customized poly mailers in the market. You can find some examples from the here.

How to Choose the Right Poly Mailer

When you are shipping a product, you want to be sure that it arrives at its destination in the same condition that it left your hands. This means that you need to use the appropriate shipping material. One option for shipping products is a poly mailer. Poly mailers provide an extra layer of protection for your product and can be used for a variety of items, including but not limited to:

  • Clothing(t-shirts, hoodies, shoes, jeans etc.)
  • Jewelry
  • Gift cards
  • Photos
  • Small electronics
  • Grocery store items
  • Toys
  • Small Tools
  • Art supplies
  • Electronics
  • Cosmetics
  • Small Furniture
  • Documents
  • Blankets

Here is a short video that demonstrates how these types of items fit to poly mailers.

When choosing a poly mailer, there are a few things to consider. The first is the size of your product. You want to make sure that the poly mailer is big enough to fit your product without being too big or too small. Extra material will add to your shipping cost. If your product is too large for the mailer, you will need to find a solution to keep it from moving around within the mailer or even potentially coming out of the mailer. This can be done by packing peanuts, bubble bags, packing foam, and paper.

The other thing to consider is how many pieces you will need. If you’re sending multiple products together, you will need one mailer for each item. If they don’t fit together nicely in the mailer, you could end up with a big, bulgy mess that is hard to ship and may cost more due to added dimensions. If your products are of different sizes but within the size limit of a single mailer, it is usually cheaper to ship them in separate mailers than to try to make one fit both.

Once you have the right size(s) in mind, here are a few factors that may affect how many items you can fit in the mailer. These may change depending on the manufacturer and type of material, so these quantities aren’t guaranteed for all types of poly mailers.

Here are some general tips for ordering the right size mailer:

  1. Figure out how many items you’ll be shipping. It’s easier to ship multiple smaller items than one big item, so you may want to divide your inventory into separate packages.
  2. Divide your poly mailers into individual compartments by using dividers or “pods.” This will ensure that if one component gets damaged in transit, the rest of your inventory will be OK. It can also help you keep your items organized.
  3. Pack heavy and/or irregularly shaped items in their own mailers to prevent damage.
  4. Use plastic bags to further protect vulnerable inventory.
  5. Ship items that are sensitive to moisture in plastic containers or in a double poly mailer.
  6. Stack mailers horizontally instead of piling them up vertically to reduce the stack’s weight.

How to Measure for the Right Poly Mailer

When you are looking for the right poly mailer for your shipping needs, it is important to measure properly. You need to make sure that the mailer is not too large or too small for the item you are trying to ship.

Here are steps for measuring poly mailer you need

  1. Measure the length, width, and height of the product you want to ship.
  2. Minimum poly mailer length : Product Length + Product Height + Product Height + Add ¼ Inch
  3. Minimum poly mailer width : Product Width + Product Height + Add ¼ Inch

For example, if you are shipping a book with dimensions  10 inches length, 6 inches width, and 1 inches height you poly mailer dimensions should be:

Minimum length: 10" + 1” + 1” + 0.25” = 12.25"
Minimum width: 6” + 1” + 0.25” = 7.25"

Finally, round up to the next whole number:

So the size needed is 13” long and 8” wide. The closest is the better but 13x9" or 13x10" should be also fine with this book.

Here are some common sizes of poly mailers and products that can be packed with:

  • 6 x 9 inches: Can fit socks, cosmetics small jewelry boxes and boxes.
  • 10x13 inches: one T-shirt, paperback novel, 2-3 pairs of socks, three-pack of boxer, 2-3 tubes of toothpaste
  • 12 x 15 inches: sweater, dress, pair of jeans, 4-5 large t-shirts

How to Ship mailer Safely

When shipping a package or mailer, you want to be sure that it arrives at its destination safely and intact. Here are some tips on how to ship your mailer securely:

  1.  Package your mailer in a sturdy box or container.
  2. Make sure that there is sufficient padding around the contents of the mailer to protect them from bumps and jostling.
  3. Use strong packing tape to seal the package shut.
  4. Label the package clearly with the destination address and any other relevant information.
  5. Ship the package using a shipping service that offers tracking and insurance.
  6. Make sure the poly mailer adhesive is strong enough.

Takeaway: Use this guide to choose the right poly mailer size for your needs, and ship your items safely and securely.


There is no one-size-fits-all answer to this question, as the best size poly mailer for your needs will vary depending on the type and weight of the items you need to mail. That said, a few general tips can help you choose the right size poly mailer for your needs:

  • Choose a poly mailer that is slightly larger than the items you need to mail.
  • If you are mailing a large number of lightweight items, choose a poly mailer with a thickness of 2 mils.
  • If you are mailing a small number of heavyweight items, choose a thicker poly mailer to provide extra support starting at 2.3 mils.
  • Use the calculation formula given above to find the best size of poly mailer for your product.
  • Make sure the poly mailer is equipped with a powerful adhesive, tear resistance and waterproof.
  • Find a poly mailers design that fits your branding, items and taste.
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