PlusPackaging Get expert help
Browse Solutions

How to Ship a Poly Mailer: A Simple Guide

Virginia Borinski Blog  |  Mailing Bags 3 min read 2/3/2025
How to Ship a Poly Mailer: A Simple Guide

Shipping items efficiently starts with choosing the right packaging, and poly mailers offer a practical solution for many shipping needs. Whether you’re sending clothing, accessories, or documents, these lightweight mailers streamline the process while keeping costs down. This guide will walk you through the essential steps to prepare, pack, and ship your items using poly mailers.

Why Use Poly Mailers for Shipping?

Poly mailers are waterproof, tear-resistant, and take up less space compared to boxes, reducing shipping costs. Businesses and individuals use poly mailers to ship clothes, accessories, documents, and more.

Styled Table
Advantages of Poly Mailers Why It Matters
Lightweight & Flexible Saves on shipping costs
Waterproof & Tear-resistant Protects against damage
Self-sealing & Tamper-proof Secure packaging
Available in Various Sizes Fits different products

Step 1: Choose the Right Poly Mailer

Selecting the right size and type of poly mailer ensures safe and cost-effective shipping.

Poly Mailer Table
Type of Poly Mailer Best for Shipping Features
Standard Poly Mailers Clothing, fabric, soft items Lightweight, water-resistant, tear-proof
Bubble Padded Poly Mailers Small electronics, books, delicate accessories Extra padding for protection
Expandable Poly Mailers Bulkier soft items (sweaters, blankets, shoes) Expands to fit larger items

πŸ’‘ Tip: If you’re shipping fragile or valuable items, consider adding extra padding or using a box inside the mailer.

Step 2: Properly Pack Your Items

  • For clothing: Fold neatly to minimize wrinkles and maximize space.
  • For small accessories: Place them in a protective pouch or bubble wrap for added security.
  • For multiple items: Use clear poly bags to keep them organized inside the mailer.
  • For fragile items: Wrap in bubble wrap and ensure there is no extra space for movement.

πŸ”Ή Pro Tip: Remove excess air from the mailer before sealing to reduce bulk and prevent accidental openings during transit.

Step 3: Seal the Poly Mailer Securely

Most poly mailers come with a self-sealing adhesive strip, but for extra security:

βœ… Reinforce the edges with packing tape (especially for heavier items).

βœ… Double-check the adhesive is firmly pressed down to avoid accidental openings.

πŸ“Œ Tip: If you plan to reuse the mailer, use a resealable poly mailer instead of one with permanent adhesive.

Step 4: Weigh & Measure the Package

Accurate weight and dimensions help determine the right shipping cost and avoid extra charges.

Shipping Measurement Table
Shipping Factor How to Measure
Weight Use a digital scale (round up to the nearest oz/lb).
Length & Width Measure the longest and widest part of the mailer.
Thickness Check if it exceeds the allowed thickness for flat-rate shipping.

πŸ“¦ Why It Matters?

Many carriers charge based on dimensional weight (size + actual weight), so keeping your package as compact as possible saves money.

Step 5: Choose the Right Poly Mailer Size

Picking the correct size ensures a snug fit for your product without excess bulk. Use this table as a reference:

Item TypeRecommended Poly Mailer Size
Apparel & Footwear
T-Shirts, Socks9″ x 12″ or 10″ x 13″
Hoodies, Sweaters12″ x 15.5″ or 14.5″ x 19″
Jeans, Pants10″ x 13″ or 12″ x 15.5″
Small Accessories (Caps, Gloves, Socks)6″ x 9″ or 9″ x 12″
Fitness Apparel9″ x 12″ or 10″ x 13″
Running Shoes, Soccer Cleats, Hiking Boots12″ x 15.5″ or 14.5″ x 19″
Ski Boots, Larger Footwear19″ x 24″ or bigger
Sports & Fitness Equipment
Baseball Gloves, Boxing Gloves10″ x 13″ or 12″ x 15.5″
Basketballs, Soccer Balls14.5″ x 19″ or larger
Tennis Rackets, Badminton Rackets12″ x 15.5″ or 14.5″ x 19″
Golf Clubs, Hockey Sticks19″ x 24″ or larger
Dumbbells, Weightlifting Belts14.5″ x 19″ or larger
Resistance Bands, Foam Rollers9″ x 12″ or 10″ x 13″
Yoga Mats19″ x 24″ or larger
Inline Skates, Skateboards19″ x 24″ or larger
Sports Watches, Fitness Trackers6″ x 9″ or 9″ x 12″
Water Bottles9″ x 12″ or 10″ x 13″
Outdoor & Adventure Gear
Camping Tents, Sleeping Bags19″ x 24″ or bigger
Fishing Rods, Kayaks19″ x 24″ or larger
Bicycles, Surfboards, Snowboards, SkisOversized shipping required
Climbing Gear, Helmets12″ x 15.5″ or larger
Hiking Backpacks, Gym Bags14.5″ x 19″ or larger
Protective & Accessories
Sports Sunglasses, Cycling Gloves6″ x 9″ or 9″ x 12″
Elbow Pads, Knee Pads9″ x 12″ or 10″ x 13″
Jerseys, Sports Caps9″ x 12″ or 10″ x 13″
Sports Towels10″ x 13″ or 12″ x 15.5″
Sports Nutrition, Protein Bars6″ x 9″ or 9″ x 12″
Golf Balls, Baseball Bats12″ x 15.5″ or 14.5″ x 19″
Paddleboards19″ x 24″ or larger
Other Items & Additional Suggestions
Musical Instruments (Guitar Accessories, Sheet Music)9″ x 12″ or 10″ x 13″
Books & Magazines9″ x 12″ or 10″ x 13″
Electronics (Small Gadgets, Earbuds, Chargers)6″ x 9″ or 9″ x 12″
Laptop Sleeves, Tablets10″ x 13″ or 12″ x 15.5″
Small Home Decor Items (Candles, Picture Frames)9″ x 12″ or 10″ x 13″
Office Supplies (Notebooks, Pens, Stationery)6″ x 9″ or 9″ x 12″

Step 6: Print & Attach the Shipping Label

Most shipping services allow you to print labels at home, saving time at the post office.

πŸ”Ή How to Attach the Label Properly:

βœ”οΈ Use a self-adhesive shipping label or clear tape to secure it.

βœ”οΈ Ensure the barcode is clearly visible and scannable (avoid wrinkles).

βœ”οΈ If reusing a mailer, remove or cover any old labels to avoid confusion.

Step 7: Choose the Best Shipping Service

Here’s a comparison of common carriers for poly mailer shipping:

CarrierBest ForEstimated Cost (Under 1 lb)Delivery Speed
USPS First ClassSmall, lightweight packages$4 – $62-5 days
USPS Priority MailHeavier packages (1-3 lbs)$8 – $121-3 days
UPS GroundLarger items or bulk orders$8 – $151-5 days
FedEx ExpressFast delivery$10 – $191-2 days

Notes:

  • Smaller items (accessories, gadgets, sunglasses, watches, etc.) fit well in 6″ x 9″ or 9″ x 12″ mailers.
  • Apparel, mid-sized equipment, and bulkier gear require 10″ x 13″ to 14.5″ x 19″ mailers.
  • Large sports gear and oversized items (bicycles, kayaks, snowboards, etc.) may require custom or oversized shipping solutions.

πŸ“Œ Pro Tip: Use flat-rate shipping options if your package is heavy but small in size.

Step 8: Drop Off or Schedule Pickup

Now that your package is ready, you have two options:

πŸš€ Drop it off at a post office, UPS, or FedEx location.

🏠 Schedule a pickup from USPS, UPS, or FedEx for convenience.

Bonus: Cost-Saving Tips for Shipping Poly Mailers

Money-Saving TipHow It Helps
Use discounted shipping platformsGet lower rates from carriers like USPS, UPS, and FedEx.
Buy poly mailers in bulkSaves money compared to buying individually.
Optimize package sizeSmaller packages = lower shipping costs.
Offer free shipping over a certain amountEncourages larger orders while keeping shipping affordable.

Where to Buy Poly Mailers

If you’re looking for high-quality poly mailers, check out Plus Packaging. With over five decades of experience, they offer a wide range of durable and customizable poly mailers designed to meet your shipping needs. Buying from a trusted supplier with a long-standing reputation ensures you get top-quality materials at competitive prices.

Final Thoughts

With the right approach, poly mailers make shipping straightforward and hassle-free. From selecting the right size to sealing it securely and picking the best shipping method, each step plays a role in ensuring your package arrives safely. Whether you’re a small business or an individual sender, using poly mailers can help you ship efficiently without unnecessary bulk or expense.