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Choosing the right poly mailer size is the first step to professional, cost-efficient shipping. The wrong size means damaged products, wasted materials, or sky-high dimensional weight charges. This guide gives you a complete poly mailer size chart — plus a simple formula to get it right every time.
What Is a Poly Mailer? (Quick Overview)
A poly mailer is a lightweight, flexible, moisture-resistant shipping bag made from synthetic film — typically LDPE, or for eco-forward brands, a PLA+PBAT compostable blend. Unlike boxes, they ship flat, weigh almost nothing, and dramatically cut your packaging cost per order.
At Richer EcoPack, we supply three main types:
- Compostable Poly Mailers — PLA+PBAT bio-based material, TÜV OK Compost certified
- Recycled Poly Mailers — made from post-consumer recycled content
- Standard LDPE Mailers — heavy-duty, moisture-proof, cost-effective
Standard Poly Mailer Sizes: Complete Size Chart
All sizes can be fully customized. Contact us for non-standard dimensions.
How to Choose the Right Poly Mailer Size
Step 1 — Measure your product (flat and folded):
- Width of mailer = product width + product depth + 1 inch (for ease of insertion)
- Length of mailer = product length + product depth + 2 inches (for the flap and seal)
Step 2 — Match by product type:
- Single T-shirt → 9" × 12" or 10" × 13"
- Hoodie / thick sweater → 12" × 15.5"
- Shoes in box → 14.5" × 19" or 19" × 24"
- Flat documents / stationery → 7.5" × 10.5"
Step 3 — Check thickness (mil):
- Standard use: 2.0–2.5 mil
- Heavy or sharp items: 3.0 mil+
Custom Sizes: When Standard Isn't Enough
If your product has unique dimensions, or you want to reduce dimensional weight to the absolute minimum, custom poly mailers wholesale is the way to go. Customization options include:
- Any dimension — width, length, gusset
- Custom printing — logo, brand colors, social handles, up to 8 colors
- Add-ons — double adhesive seal strip, tear notch, handle cut-out
Custom sizing can reduce your per-shipment packaging cost significantly. Contact our team for a tailored quote.
Eco-Friendly Poly Mailer Options
Modern brands are choosing packaging that reflects their values. Richer EcoPack offers:
1. Compostable Poly Mailers (PLA+PBAT) Made from plant-based materials. Certified to TÜV OK Compost. Breaks down in composting conditions — no toxic residue.
2. Recycled Content Mailers Made from post-consumer recycled (PCR) plastics. Keeps existing plastic in circulation rather than creating demand for virgin materials.
Both options can be fully custom printed. For fragile items, consider our Honeycomb Mailer Bags for added cushioning.
FAQ
Q: How do I measure a product for a poly mailer? Measure the product's length, width, and depth (when folded/packed). Apply the formula: Width = product width + depth + 1"; Length = product length + depth + 2".
Q: What is the most common poly mailer size? The 10" × 13" is the industry standard — it fits most single apparel items including shirts, leggings, and light sweaters.
Q: Can I ship fragile items in a poly mailer? Standard poly mailers offer no cushioning. For fragile items, use our Honeycomb Mailer Bags or add protective wrap inside.
Q: Are poly mailers waterproof? Yes — LDPE and PLA+PBAT materials are moisture-resistant and protect contents from rain and humidity during transit.
Q: What's the difference between compostable and recycled poly mailers? Compostable mailers break down in composting environments; recycled mailers keep existing plastic in circulation. See our Recycled vs Compostable Poly Mailers guide for a full comparison.
Ready to upgrade your shipping packaging? Request a free sample to test size and quality before committing to a bulk order.
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