Selecting the right packaging is essential to prevent product damage and mishandling during transit.
In 2026, USPS is expected to deliver 6.5-6.8 billion packages, UPS roughly 4.3-4.5 billion, and FedEx about 3.7-3.8 billion. Together, these three carriers are projected to ship around 14.8 billion packages. With rising additional fees-led by dimensional weight charges-proper product packaging has never been more critical.
If you ever ship packages, you should know some basic facts about shipping mailers. Understanding your packaging options helps you pick the most cost-effective mailer type and size every time.
Keep reading to learn how to select the ideal packaging for your products and avoid unnecessary fees.
Picking a Mailer Size
Picking the appropriate size for your mailer is important. You should choose the mailer size that is closest to the size of your item. Use a ruler or tape measure to determine the length, width, and depth of your item.
When you know the dimensions of your item you can look for a similarly sized mailer. For instance, when mailing a standard 8.5 x 11 inch document, a 9 x 12 inch flat envelope provides the optimal fit. Allow for the thickness of your item when figuring out what size mailer you need. If you have a thick item you may opt for a 10 inch x 14 inch mailer instead.
If your mailer is much bigger than your item, your item will slide around as it travels. This could cause it to break or wrinkle. Oversized mailers increase shipping costs by triggering dimensional weight surcharges. On the other hand, a mailer that is too small won't protect your item from the rough handling of postal carriers.
If you can't find a mailer that is an appropriate size for your needs, look for a padded mailer in a size up. You need to size up when using bubble envelopes. Because of their padding, the usable space inside the envelope is smaller than the exterior dimensions of the envelope. If you need to size up on a bubble mailer you can always cut it down some. Padded mailers are not as easy to size down, as the filling can get messy.
Picking a Mailer Type
Size isn't the only factor to consider when choosing a mailer. You should also think about the contents that you are shipping. What materials and mailer shapes are best suited to your shipping needs?
Listed below are some of the most common kinds of mailers and envelopes, along with the items they fit best.
Corrugated Mailers
Corrugated mailers are designed to hold specific items. They come in sizes that fit the average dimensions of things like documents, photos, and paintings.
These mailers are strong and lightweight, which makes them great for shipping small and fragile items. They are designed with folds and flaps that make them sturdy and hard to crush.
Corrugated mailers are usually purchased unassembled. It takes just a few folds to turn them from a flat piece of cardboard into a compact shipping box. No tape or staples required!
Because of their compact rectangular shape, these mailers are also great for storing items in.
Outside Tuck Cardboard
Outside tuck boxes are a variety of corrugated mailers. As the name would suggest, they feature flaps that tuck into the outside of the box. This way, you can pack a box without worrying that the flaps might damage its contents upon closure.
Outside tuck boxes are sturdy and lightweight and are great for items that fit snugly into the box.
Bookfolds
Bookfolds are another kind of corrugated mailer. They are a great choice if you are shipping books or magazines. Bookfolds work best with items that have a depth of 5 inches or less.
Unlike many other corrugated mailers, you need to use tape when assembling bookfolds.
Literature Mailers
If you're shipping a book, you can also use a literature mailer. These mailers come in a variety of sizes that fit hardcovers, paperbacks, picture books, and everything in between. They also work for magazines, framed photos, and folios.
Like corrugated mailers, literature mailers are sturdy and easy to assemble. They do not require any tape, staples, or glue. Their strong sides protect whatever literature you've put inside of them.
When mailing books, consider using a heat-sealed poly bag to make your package weather proof. Simply put your mailer in the bag with your shipping label attached and impulse seal it closed. This also makes the package tamper evident.
Poly Shipping Mailers
Poly mailers are durable and lightweight shipping bags made of polyethylene. They are weatherproof and protect against dirt, dust, and moisture. They are self-sealable and easy to store.
Poly mailers are made of thin material and do not offer much padding. For this reason, they are best for shipping soft items like clothing. However, there are some varieties of poly mailers that have protective bubble lining.
Poly mailers are also used for shipping magazines and catalogs. In these cases, a clear mailer is usually fixed around the piece of media.
Tyvek Envelopes
Like poly and nylon mailers, Tyvek envelopes are weatherproof and tear-resistant. They are also very sturdy. Because of the strength of Tyvek material, these envelopes are great for shipping important documents.
Tyvek envelopes come in a variety of sizes and shapes. These include commercial envelopes, CD sleeves, and extra-large envelopes. You can also customize them to fit your specific needs.
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