ZaroMailer

Custom Poly Mailers - Branded Shipping Bags with Full-Color Printing

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Free shipping included Free digital proof 100% recyclable
Custom Poly Mailers

A custom flat poly mailer layout for non-fragile apparel and soft goods.

Poly mailing bag without bubble cushioning.
Customize & Check Prices
Quantity
Size
Price includes up to 2 colors and full bleed printing.
Turnaround
Price per unit:$0.1595
Total:$1,595.00
Contact Our Team
Total$1,595.00
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Specification Overview FAQ Reviews
Custom printed poly mailers are flat, lightweight mailing envelopes built for eCommerce brands shipping apparel and other soft goods. Made from a durable, moisture-resistant multi-layer polyethylene blend, they offer a sturdy alternative to bulky carton packaging while keeping shipping weight and postage cost down. Each mailer comes with a self-sealing strip for fast, tamper-evident closure, and ZaroMailer prints your logo and brand colors directly onto the exterior for a polished, professional look. The outer layer resists water, impact, punctures, and tears, so contents arrive the way they left your warehouse. These mailers are made entirely from recycled content, staying fully recyclable and biodegradable from start to finish.

Product Specifications

Material
Long-lasting, tear-resistant multi-ply poly film
Closure Type
Self-adhesive sealing strip
Printing
Full-bleed print, up to 2 colors included
Environmental
100% recyclable, crafted from recycled materials

Sizes, Print Areas & Recommended Use

SIZE (IN) SAFE PRINT AREA RECOMMENDED USE
6 x 9 5.5 x 8.5 Jewelry, accessories, small softgoods, cosmetics
9 x 12 8.5 x 11.5 T-shirts, single apparel items, books
10 x 13 9.5 x 12.5 Sweaters, hoodies, activewear, multi-item orders
12 x 15.5 11.5 x 15 Jackets, larger apparel, boxed soft goods
14 x 17 13.5 x 16.5 Bulkier apparel, bedding, oversized orders
19 x 24 18.5 x 23.5 Large textiles, multi-item ecommerce shipments
24 x 24 23.5 x 23.5 Oversized square soft goods and flat packs

Frequently Asked Questions About Custom Poly Mailers

What is the minimum order quantity (MOQ) for custom poly mailers?
Our MOQ for custom printed poly mailers is 5,000 units per size. This keeps per-unit pricing affordable while staying accessible for growing e-commerce brands. New to custom packaging? Check out our guide, A Beginner’s Guide to Custom Packaging for Small Brands.
Can I order a sample before placing a bulk order?
Yes. We recommend approving a digital proof before your full order goes into production. Digital proofs are included free with every order, and physical samples can be arranged on request so you can check material weight, print color, and overall feel before committing to a bulk run.
What hidden fees should I expect when ordering custom poly mailers?
There are no hidden fees at Zaro Mailer - shipping, your first plate charge, and sales tax are all included. Many suppliers charge these separately, along with setup fees, freight, customs, or color matching. For a full cost breakdown, see our Custom Packaging Pricing Guide.
How do I vet a custom packaging supplier before a large order?
Look into quality consistency across reorders, material and thickness guarantees, reprint and defect policies, capacity during peak season, and lead times confirmed in writing. Also check whether shipping, taxes, and setup costs are already included in the quote. Our full checklist is in Questions to Ask Before Choosing a Packaging Supplier.
How long does the full process take from design approval to delivery?
Once your artwork is approved, standard turnaround runs 8-13 weeks with free shipping by boat. Rush air freight is available if you need stock sooner. Plan for an extra 3-7 days at the start for design review and proofing.
How are custom poly mailers made?
Custom poly mailers are made from a multi-layer polyethylene film that’s die-cut into a flat envelope shape, then printed with your artwork on the outer surface. A self-seal adhesive strip is added to the flap before the mailers are folded, packed, and shipped.
Where can I order custom poly mailers with my logo?
You can order custom poly mailers with your logo directly through Zaro Mailer. Send us your artwork or logo files, and our team will prepare a proof for your approval. Free shipping is included.
How do I customize poly mailers?
Send us your logo, text, and artwork layout for the front and back of the mailer, or upload a print-ready file if you already have one ready. We print your design in full color across the mailer, with up to 2 colors included.
How much do custom poly mailers cost?
Pricing depends on size and order quantity, and larger orders bring the per-unit cost down. Free shipping is always included, and you can check live pricing for each size and quantity option above.
Are custom poly mailers eco-friendly?
Yes. Our custom poly mailers are made with 100% recycled content, are fully recyclable, and are naturally biodegradable. We also use water-based, low-VOC inks that are gentler on the environment than traditional solvent-based inks.
Can I use custom poly mailers to ship to Amazon customers?
Yes. Custom poly mailers work well for Amazon FBM, Seller Fulfilled Prime, and merchant-fulfilled orders, and they meet standard carrier requirements for USPS, UPS, and FedEx. If you’re shipping into FBA, double-check Amazon’s current packaging prep requirements first.
What sizes are available?
We carry a range of sizes to fit different shipping needs. Check the size selector above to see all current options.
Are these mailers waterproof?
Yes. Our custom poly mailers are built from a water-resistant film that keeps your products protected from moisture, rain, and humidity while in transit.
I’m not a designer - can I design custom poly mailers myself?
Absolutely. Free tools like Canva work well for putting together a professional mailer design. The key things to get right are 300 DPI resolution, CMYK color mode, 0.125" bleed on all sides, and keeping text and logos at least 0.25" inside the cut line. If you’d rather not handle it yourself, just send us your logo and ideas and our team can help build the layout.
What design software should I use?
Canva works well if you’re just getting started. Adobe Illustrator is the industry standard for vector work. Figma is a solid option for teams collaborating on a design together. All three can produce print-ready files at 300 DPI in CMYK with proper bleed.
What resolution should my artwork be?
300 DPI at final print size is the minimum you’ll want. Anything at 72 DPI will come out blurry once printed. If you’re working at 50% scale, the file needs to be 600 DPI at that smaller size to equal 300 DPI at full size.
What is bleed, and do I need it?
Bleed is the extra bit of artwork that extends past the final cut line. The standard is 0.125" on all sides, so a 10" x 13" mailer needs artwork sized at 10.25" x 13.25". Always extend background colors and patterns out to the bleed edge.
Should I design in CMYK or RGB?
Always design in CMYK. Your screen shows colors in RGB, but printing uses CMYK, so working in CMYK from the start gives you a much closer preview of how the final colors will actually print.
Should I use vector files or images?
Vector files (AI, EPS, SVG) are the better choice for logos, text, and graphics since they scale to any size without losing quality. For photos, high-resolution raster images at 300 DPI work fine. Convert any text to outlines before sending the file over.
Can I print different designs on the front and back?
Yes. Many brands use a main design on the front and a simpler design, care instructions, or logo on the back. Send us your layout for the front, back, and flap and we’ll set it up.
Can I add seasonal designs or promotional messages?
Yes. Custom poly mailers can be updated anytime with seasonal designs, promotional messages, or limited-edition artwork to keep your packaging feeling fresh.
What file format should I send to the printer?
AI (Adobe Illustrator) is the industry standard. EPS and print-ready PDF files with proper bleed settings also work well. When you order through Zaro Mailer, just send over your file and our team will handle the file prep.
Should I test print before ordering in bulk?
Yes, always. Request a sample or a single test print first. Check that the color looks accurate, the design fits the mailer properly, all text is readable, and the overall look holds up before committing to a full production run.

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Volume Pricing — 6"x9"

Per-unit price drops as quantity goes up. Free shipping included at every tier.

Select a different size above to update this table.
QuantityTotalPer mailerYou save
10,000 $1,595.00 $0.1595 —
15,000 $2,392.50 $0.1595 Save 0%
20,000 $3,190.00 $0.1595 Save 0%
25,000 $3,987.50 $0.1595 Save 0%
30,000 $4,785.00 $0.1595 Save 0%
35,000 $5,582.50 $0.1595 Save 0%
40,000 $6,380.00 $0.1595 Save 0%
45,000 $7,177.50 $0.1595 Save 0%
50,000 $7,975.00 $0.1595 Save 0%

Custom Poly Mailers for E-Commerce Brands

Lightweight doesn't have to mean flimsy. Our custom poly mailers are built to resist tears and water while keeping your shipping costs down, making them the practical choice for brands sending clothing, accessories, books, or soft goods. Full-color edge-to-edge printing turns every package into a piece of your brand, not just a container for what's inside.

Self-seal closure, free shipping, and full bleed printing are included on every order at ZaroMailer — no upgrades, no extra fees. Need cushioning for something fragile? Our bubble mailers add that protection, and our paper mailers offer a more eco-friendly route when that matters more than durability. Browse the full lineup of custom packaging, or if you're not sure which option fits your product, request a free quote and we'll help you figure it out.

Custom Poly Mailers for E-Commerce Brands

Why Order Custom Poly Mailers from ZaroMailer?

Shipping Cost

No hidden delivery fees at checkout.

Plate Charge

Your first printing plate fee is completely on us.

Sales Tax

Transparent pricing with no surprise costs.

Full Bleed and Up to 2 Colors

Make a bold visual impact with full-bleed printing that extends edge-to-edge across your mailers. We include up to 2 ink colors in every order, ensuring your logos and branding elements stay crisp, vibrant, and professional.

Both Side with Customized Print

Maximize your marketing real estate by printing on both the front and back of your mailers. Use one side for your primary logo and the other for social links, discount codes, or brand messaging.

Self Seal

Integrated peel-and-stick adhesive for seamless, tamper-resistant packaging.

Earth Friendly

Crafted from 100% recycled content, fully recyclable and naturally biodegradable - packaging that's as responsible as it is durable.

Free Design

Not sure where to start? Tell us your vision and our design team will create your custom artwork from scratch, completely free.

Marketing Ideas for Custom Poly Mailers

Every shipment is a chance to remind customers who sent it. Here's how ecommerce brands make their custom poly mailers work harder:

QR codes on the flap

Send customers straight to a product tutorial, a care guide, or a code for their next order - all from one scan on the flap.

Social handles & hashtags

A branded hashtag next to your Instagram or TikTok handle gives customers an easy reason to post their unboxing and tag you in it.

Seasonal & limited editions

Swap in new artwork for holidays, product launches, or campaigns so returning customers always have something new to notice and share.

Referral & repeat offers

Skip the insert card - print your referral code or free-shipping offer right on the mailer where customers can't miss it.

Thank-you messaging

A short, genuine thank-you inside the flap turns a plain shipping bag into something customers actually remember getting.

Unboxing-ready design

Strong colors and a distinctive interior print make the mailer worth filming - built for the kind of unboxing video customers want to share.

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Our Customers

Over the years, we've earned the trust of businesses of every size. Whether you need a single mailer or thousands, you can rely on us for all your packaging needs.

Girl Scouts logo
Damart logo
DHL logo
EMS logo
FedEx logo
PMD logo
Jeep logo