Padded Mailers

A padded mailer is a cushioned mailer envelope. They can be constructed from polyethylene (plastic) or paper, and feature some type of padding, whether that be bubbled air pockets or shredded newsprint. These cushioned mailers are designed to protect fragile items in transit.

Paper padded mailers are curbside recyclable. Plastic padded mailers are recyclable with thin film (#2 and #4 stretch film plastics). Many consumers have access to thin film recycling at local grocery stores. Curbside recycling is not widely available.

Check out our Ultimate Guide to Protective Mailers for more information.

We offer five mailer sizes. How to best match our options with your outbound orders?

First, lay the item(s) you need to ship on a table and measure an “imaginary boundary” around it to get the length, width, and height. Next, add a reasonable allowance around these dimensions. If you want a snug fit, add 0.125 to the length and width for boxes and 0.25 for mailers. If your item is thick (0.125” or more), add at least 0.5 to your dimensions. Finally, with the cushioning included, map these dimensions to one of our five mailer sizes, rounding up (not down).

If you’re unsure, we strongly recommend ordering free samples so you can feel, fit and test before you place your entire order. Also, learn more about right-sizing your packaging to avoid incurring extra costs and using additional materials.

Because of these mailers’ cushioned and uneven exterior, some brands have faced concerns about how well traditional labels stick to them. If you struggle with labels adhering to the mailer's surface, shop our High Tack Direct Thermal Labels, which have exceptional adhesion to all paper, including recycled and cushioned mailers. Please consult our Printer Compatibility Guide to ensure these labels work for your printer.

In your pursuit of sustainable packaging, deciding between paper and plastic, especially recycled paper and recycled plastic, is not as cut and dried as it seems. On the one hand, recycled paper is more circular (because it is made with 100% recycled content and is easily recycled curbside). It is also naturally biodegradable, which means it would never become litter on land or in the ocean. On the other hand, recycled poly packaging tends to be significantly lighter than its paper counterparts, which means it has a substantially lower carbon footprint.

We stand behind both of our cushioned mailers and have seen different brands - all highly committed to sustainability - make different choices between the two. In general, our guidance is to choose 100% Recycled Padded Mailers if your goal is circularity, curbside recyclability, or natural biodegradability. On the other hand, if minimizing your carbon footprint is your primary goal, choose our 50% Recycled Bubble Mailers.

A host of new cushioned paper mailer options have been introduced into the market, including Amazon’s protective mailer, which features two layers of kraft linerboard that sandwich an expanded poly material. This poly material is present in a small enough weight that the entire package is curbside recyclable. EcoEnclose has studied these mailers closely and has even been in close R&D dialogues with many of these product developers.

Unfortunately, we have determined that none currently meets our standards because they utilize 100% virgin inputs. On the other hand, our padded envelopes are made with 100% recycled content, making them an eco-friendly alternative to mailers on the market.

EcoEnclose is committed to pursuing paper-based packaging strategies that do not lead to the destruction of old-growth forests. In addition this commitment, we know that virgin paper has 3.8x the carbon footprint of recycled alternatives.

Many eCommerce businesses are shifting from boxes to mailers, and when they make this switch, they often find that protective, cushioned mailers are their best bet.

Why? Mainly due to cost and operational simplicity. Protective mailers are cheaper to buy and ship and more operationally efficient. However, shipping boxes offer better protection and presentation. Learn about the pros and cons of mailers and shipping boxes.

Padded envelopes are made with two layers of 100% recycled (20% post-consumer waste) kraft paper that sandwich a layer of macerated newsprint. This recycled newsprint is collected from local recyclers and shredded on site where the mailers are made.

This padded envelope features a tear strip that is made out of plastic. While we recommend against composting any eCommerce packaging (recycling is far better for the environment), we know these mailers are technically compostable as long as the red plastic tear strip is removed. While we hope to transition this tear strip to a non-plastic but equally sturdy material over time, we recognize how vital this tear strip is to the overall functionality of the mailer as it allows a recipient to easily open the mailer without getting into the macerated paper layer.

Yes! Padded envelopes look gorgeous when custom branded. When you work with EcoEnclose, you have the option to customize these protective mailers starting at 500 units. Read our mailer artwork guidelines.

Customization significantly expands starting at 15,000 units. Request a high-volume quote.