Poly mailers are the cheapest and lightest option for soft, unbreakable items such as clothing, and they rarely trigger dimensional weight charges. Padded mailers add light protection for small items. Boxes cost more and can raise billable weight, but they protect fragile, rigid or stackable products and give more space for branding. Choose by what breaks, not by habit.
The package type sets your material cost, your postage and your damage rate. Here is how they compare.
Side by side
| Poly mailer | Padded mailer | Corrugated box | |
|---|---|---|---|
| Material cost | Lowest | Low | Higher |
| Weight | Lightest | Light | Heaviest |
| Dimensional weight risk | Low | Low | Higher |
| Crush protection | None | Little | Good |
| Water resistance | Good | Varies | Poor unless coated |
| Branding space | Printed bag | Printed bag | Printed box and interior |
| Recycling | Store drop-off film | Mixed materials can be hard to recycle | Curbside |
Decision table
| Product | Use |
|---|---|
| Apparel, textiles | Poly mailer |
| Books, flat items | Rigid or padded mailer |
| Small accessories | Padded mailer or small box |
| Cosmetics, glass, ceramics | Box with padding |
| Electronics | Box with padding |
| Subscription and gift orders | Box, often a custom mailer box |
The hidden costs
Damage is a cost too: a replacement, return shipping and a lost customer. Track damage rates when switching packaging. And remember that a box only costs more in postage when its dimensional weight exceeds its real weight; see dimensional weight.
Put your choice into the cost per shipment math. Browse shipping and fulfillment.
Common questions
Can I ship clothing in a poly mailer?
Yes. Poly mailers are the standard for apparel and other soft goods.
Are poly mailers recyclable?
Many are made from LDPE and accepted at store drop-off film recycling, not curbside. Paper mailers are curbside recyclable in most areas.
When do I need a box instead of a mailer?
For anything fragile, rigid, liquid, heavy or likely to crush, and for products whose packaging must arrive undamaged.
Are padded mailers enough for electronics?
Only for small, sturdy items. Most electronics should ship in a box with padding.