Plastic Shipping Envelopes: Types, Sizes, and What They Cost by the Case
Key takeaways
- Plastic shipping envelope, plastic mailer, polyethylene envelope and poly mailer all name the same self-seal bag.
- 2.0 mil is the everyday standard; 2.5 mil adds puncture resistance for heavier or sharp-edged orders.
- By the case: $0.030 per 6×9 mailer up to $0.25 per 24×24, with 10×13 at $0.045 (2.0 mil).
Plastic shipping envelopes, plastic mailers, polyethylene envelopes and poly mailers are all the same product: a tear-resistant polyethylene bag with a self-seal strip, made to ship soft and non-fragile goods without a box. They run from 5×7 to 24×24 inches, in 2.0 or 2.5 mil film, and cost $0.03 to $0.25 each by the case on the ProntoPack store.
What is a plastic shipping envelope made of?
Polyethylene film, white on the ProntoPack store. The film is blown to a set thickness, measured in mil (one thousandth of an inch). A 2.0 mil mailer is the everyday standard for apparel and soft goods; 2.5 mil adds puncture resistance for heavier or sharp-edged items and multi-item orders. Both are water-resistant, weigh a fraction of a box, and seal with a peel-off adhesive strip, no tape needed.
We extrude and convert poly mailers on our own lines in Tijuana, Mexico, and stock U.S.-made poly from our manufacturing partners, so everything on the store ships from U.S. inventory.
Which plastic mailer size do I need?
Measure the item flat, then add about 2 inches to the width and 3 inches to the length for the seal and the item's thickness. Two sizes cover most apparel operations: 10×13 for one to three garments, and 12×15.5 for hoodies, jeans and multi-item orders. The full poly mailer size chart lists what fits in every size from 6×9 to 24×24.
What do plastic mailers cost by the case?
Store prices for white, self-seal poly mailers in the two standard films:
| Size | Case | 2.0 mil case price (per mailer) | 2.5 mil case price (per mailer) |
|---|---|---|---|
| 6 × 9 in | 1,000 | $29.99 ($0.030) | $34.99 ($0.035) |
| 7.5 × 10.5 in | 1,000 | $36.99 ($0.037) | $42.99 ($0.043) |
| 9 × 12 in | 1,000 | $42.99 ($0.043) | $49.99 ($0.050) |
| 10 × 13 in | 1,000 | $44.99 ($0.045) | $54.99 ($0.055) |
| 12 × 15.5 in | 500 | $32.99 ($0.066) | $38.99 ($0.078) |
| 14.5 × 19 in | 500 | $46.99 ($0.094) | $54.99 ($0.110) |
| 19 × 24 in | 200 | $34.99 ($0.175) | $39.99 ($0.200) |
| 24 × 24 in | 200 | $44.99 ($0.225) | $49.99 ($0.250) |
By the pallet (about 35,000 flat mailers) pricing drops a further 9% to 20% depending on tier; see how bulk poly mailer pricing works.
Plastic envelopes vs. bubble mailers vs. paper
If the item survives a 3-foot drop onto concrete, a flat plastic mailer is the cheapest and lightest option. If it needs light cushioning (boxed cosmetics, books, accessories), step up to a bubble mailer. If the brand is paper-forward, a paper mailer trades some water resistance for a recyclable unboxing. The three-way comparison has the decision tree.
Can plastic shipping envelopes be printed?
Yes. Custom-printed poly mailers start at 25,000 pieces (50,000 for the smallest sizes), with a free digital proof in 48 hours and production in 5 to 7 business days after approval. Details on the custom printing page.
FAQ
Are plastic mailers and poly mailers the same thing? Yes. Plastic mailers, plastic shipping envelopes, polyethylene envelopes and poly mailers are different names for the same polyethylene self-seal bag.
How much does a 10x13 plastic mailer cost? On the ProntoPack store, $44.99 per 1,000 for 2.0 mil ($0.045 each) or $54.99 per 1,000 for 2.5 mil ($0.055 each). Pallet pricing is lower.
Are plastic shipping envelopes waterproof? They are water-resistant: the polyethylene film sheds rain and the self-seal strip closes the opening. They are not rated for submersion.
What thickness plastic mailer should I use for clothing? 2.0 mil for most apparel. Use 2.5 mil for heavier items, sharp-edged packaging inside, or multi-item orders.
Buying at volume?
Our wholesale line sheet publishes per-unit pricing by pallet tier — no quote request needed to see numbers. Want to touch the product first? The $29 sample kit covers six product lines and is credited in full against your first wholesale order.
See the line sheetOrder the $29 sample kit
Questions? Call (619) 703-0245 — we manufacture our poly & bubble mailers in Tijuana and ship from U.S. inventory.