Branded mailers turn a shipment into an unboxing — but the first question every seller asks is “what's the minimum I have to order?” Here's how custom-print minimums actually work, and how to plan a run that makes sense.
Why there's a minimum at all
Custom mailers are printed flexographically: your artwork is turned into printing plates, the press is set up and color-matched, then it runs. That setup cost is the same whether you print 5,000 bags or 500,000 — so minimums exist to spread the setup across enough units to keep the per-piece cost sane. It's the same reason a print shop won't make you 50 custom business cards for a nickel each.
Typical minimums
- 25,000 pieces is a common starting point for most sizes.
- 50,000 pieces is typical for the smallest sizes (there's more setup relative to material).
- Larger sizes and more colors can shift the minimum.
These sound big, but for an active shipper they're often just a few months of volume — and the per-unit cost at that scale is factory-direct.
What drives your MOQ and price
- Size — more film per bag.
- Number of colors — each spot color is a plate and a press station. Fewer colors, lower cost.
- One side vs. two — printing the back adds setup.
A clean 1–2 color logo on the front is the most economical way to start; you can always add colors on a reorder.
How to plan your first run
Pick your single highest-volume size and print that one first — don't spread a first order across five sizes. Nail the design, prove the reorder cadence, then expand. And keep buying stock (unprinted) mailers for your lower-volume sizes so you're not forced into custom minimums on every SKU.
Preview it before you commit
Our Custom Printing tool lets you drop your artwork onto a poly or bubble mailer and see it in seconds — up to 8 spot colors, one or both sides — then request a free print-ready proof within 48 hours. Scaling volume? Add your sizes to the wholesale quote builder for factory-direct pricing. New customers: 10% off a first order with PRONTO10.