A poly mailer is a lightweight, flexible, and durable plastic envelope commonly used for shipping soft goods like apparel. These shipping containers offer an efficient alternative to corrugated boxes by reducing weight and volume, which directly translates to lower shipping costs for e-commerce businesses and individual sellers. Selecting the correctly sized mailer is an important step in the fulfillment process, balancing protection, presentation, and profitability. This guide provides a practical approach to determining the appropriate poly mailer dimensions for various types of clothing.
Why Choosing the Right Mailer Size is Critical
Selecting an improperly sized mailer negatively impacts both the seller’s finances and the customer experience. Shipping carriers use dimensional weight calculations, meaning an oversized mailer with excess empty space can increase the calculated shipping cost beyond the actual weight of the garment. If a mailer is too large, the item shifts during transit, leading to clothing arriving wrinkled. Conversely, a mailer that is too small forces tight compression, stressing seams and risking a tear during handling.
How to Accurately Measure Clothing for Shipping
Determining the final dimensions of the packaged item is essential before selecting a mailer. The garment should first be folded or rolled exactly as it will be placed inside the mailer for shipment. Measure its length and width at the widest points. The most frequently overlooked measurement is the height or thickness of the folded clothing, which represents the package’s bulk. This depth measurement is relevant for items like sweaters or jackets that compress less easily than t-shirts. The mailer’s dimensions must be slightly greater than these measurements to allow for easy insertion and a clean seal.
Standard Poly Mailer Sizes for Apparel
The industry relies on a set of standard sizes that accommodate the majority of apparel items, ranging from petite accessories to large outerwear. Understanding these common dimensions helps streamline the inventory of shipping supplies for frequent sellers.
Mailers for Small Items
Small-format mailers, such as the 6×9 inch or 7.5×10.5 inch sizes, are suitable for single, lightweight items. These dimensions easily hold a single t-shirt, a scarf, a pair of socks, or small undergarments when folded compactly. The narrow profile of these mailers minimizes bulk and is often the most economical choice for single-item shipping.
Mailers for Medium Items
The mid-range sizes, typically 10×13 inches or 12×15.5 inches, represent the most common dimensions in apparel e-commerce. A 10×13 inch mailer can comfortably fit a pair of folded jeans, a lightweight hoodie, or two to three compacted t-shirts. The slightly larger 12×15.5 inch option is ideal for bulkier single items like a standard sweatshirt, a dress, or a small order containing a mix of a shirt and a pair of leggings.
Mailers for Large or Bulky Items
When shipping multiple garments or heavy outerwear, larger sizes are necessary. The 14.5×19 inch and 19×24 inch mailers are designated for these bulkier shipments. A 14.5×19 inch mailer is frequently used for winter coats, tailored blazers, or orders containing three to four complete outfits. The 19×24 inch size is reserved for exceptionally bulky items, such as multi-layered ski jackets, or high-volume orders approaching the maximum allowable size for standard ground shipping services.
Specialty Sizes for Oddly Shaped Clothing
Some items require non-traditional mailer dimensions to ensure they fit without excessive folding or compression. Long, narrow items like certain boots or cylindrical items often benefit from dimensions such as 9×12 inches with a gusset or a 14×20 inch size. Items like hats or shoes, which cannot be compressed without losing their shape, may require a box or a padded bubble mailer instead of a standard poly mailer.
Factors That Influence Mailer Size Selection
The general size recommendations serve as a starting point, but several variables require the seller to adjust the final mailer choice. The inherent bulk of the garment is a key consideration; a fleece jacket requires a larger mailer than a silk blouse, even if their folded length and width are similar. Different folding techniques also influence the necessary size, as a tight roll technique may allow an item to fit into a smaller mailer compared to a flat, traditional fold.
Internal packaging also affects dimensions. Materials like thick tissue paper, protective plastic bags, or branded inserts increase the overall thickness of the package. When these elements are included, select a mailer one size larger than the minimum calculated dimension to accommodate the added bulk and ensure a smooth packaging process.
Choosing the Right Poly Mailer Material and Thickness
Beyond size, the composition and gauge of the poly mailer film affect the item’s protection and aesthetic quality. Mailer thickness is measured in Mils, with standard e-commerce poly mailers typically ranging from 2.0 to 3.0 Mil. A 2.5 Mil mailer offers a balance of durability and low weight for most standard apparel, while heavier items or those traveling long distances may benefit from a 3.0 Mil thickness for increased tear resistance.
Standard poly mailers are best suited for soft goods that resist crushing. Padded mailers, also known as bubble mailers, should be used for garments with delicate or rigid components, such as clothing featuring sequins or metal buttons. The interior cushioning protects these elements from impact damage. Sellers must also decide between opaque and clear mailers; opaque mailers provide privacy and security, while clear mailers are generally avoided for direct customer shipping.
Best Practices for Packaging Clothes in Mailers
Proper packaging techniques maximize both the protection of the clothing and the efficiency of the shipment. Before sealing the mailer, place the clothing inside a separate inner poly bag or wrap it in tissue paper. This secondary layer offers protection against condensation, dust, and dirt that might penetrate the outer mailer during handling.
To save space and reduce shipping costs, compress the air out of the package before fully sealing the adhesive strip. The goal is to make the package as flat and compact as possible without damaging the item inside. Finally, ensure the self-sealing strip is pressed down firmly to prevent accidental opening during transit, and affix the shipping label securely to a flat surface of the mailer.