Poly Mailers, Boxes or Padded Envelopes: Which Packaging Suits Your Products?

The packaging you choose affects how your parcels arrive, how much you spend on materials and postage, and even how customers feel when they open their order. There's no single best option. It depends on what you're sending. Here's a straightforward comparison of the three most popular choices.

Poly mailing bags

Poly mailers are lightweight plastic bags with a self-seal strip. They're quick to pack, take up very little storage space and add almost nothing to the weight of a parcel.

Best for: clothing, textiles, soft accessories and other unbreakable items.

Pros:

• Very low cost per unit, especially in bulk
• Lightweight, which can help keep postage down
• Water-resistant and tear-resistant
• Fast to pack and easy to store

Cons:

• No cushioning, so not suitable for fragile items
• Can't protect against crushing

Cardboard boxes

Boxes offer the most protection and structure. They hold their shape, stack well in transit and can be filled with void fill or wrapping for extra cushioning.

Best for: fragile, rigid, heavy or oddly shaped items, gift sets and multi-item orders.

Pros:

• Strong protection against knocks and crushing
• Widely recyclable
• Feels premium and works well for unboxing

Cons:

• Heavier and bulkier, which can increase postage
• Takes more storage space and more time to pack
• Usually costs more per unit

Padded envelopes

Padded envelopes, often lined with bubble wrap or paper padding, sit in the middle. They're slim like a mailing bag but add a layer of cushioning.

Best for: small items that need light protection, such as phone accessories, cables, jewellery, books, cosmetics and small electronics.

Pros:

• Built-in cushioning without the bulk of a box
• Slim profile can help keep parcels in lower postage bands
• Quick to pack

Cons:

• Limited protection against crushing
• Not ideal for larger or very fragile items

Quick decision guide

• Soft and unbreakable? Use a poly mailing bag.
• Small and needs a little protection? Use a padded envelope.
• Fragile, heavy or high value? Use a box with suitable void fill.

Tips to keep packaging costs down

• Choose packaging that fits your product closely, so you're not paying to post empty space.
• Standardise on a few sizes of each type and buy them in bulk.
• Check your carrier's size and weight bands and choose packaging that keeps common orders in the cheapest band.
• Keep a small stock of each type so you're ready for any order.

Stock up on the essentials

Browse our mailing bags and envelopes, or get in touch for bulk and trade pricing.