How To Pack a Mailer for Shipping: Complete Guide To Packing Bubble and Poly Mailers

WH Global Pack blog

In today’s fast-paced world, the ability to ship items efficiently and securely has become a cornerstone of both business and personal exchanges. The rise of online shopping and global distribution networks has placed an even greater emphasis on reliable packing solutions.

This guide aims to demystify the process, providing practical and easy-to-follow advice for using bubble and poly mailers – two of the most popular choices in mail packaging.

Why Bubble and Poly Mailers?

Bubble mailers and poly mailers are favored for their lightweight, cost-effective, and protective qualities. They are versatile, easy to store, and provide significant savings on shipping costs due to their lightweight.

Whether you are a small business owner, an online seller, or simply sending a gift to a loved one, understanding how to effectively use these mailers is essential.

Why Proper Packing is Crucial For Mailers?

Packing mailers correctly serves multiple vital purposes:

●Prevents damage – Items packed tightly with sufficient cushioning are less likely to shift and get damaged inside the mailer.
●Security – A well-packed mailer keeps contents concealed and closed against tampering.
●Delivery – Neat, securely packed mailers are easier for postal services to process.
●Claims – You need to pack according to regulations to qualify for insurance claims if damage does occur.

So, learning how to pack mailers properly protects your shipments.

Steps for Packing with Bubble Mailers

Step1: Measure Your Item

Start by accurately measuring the dimensions of the item you intend to ship. This measurement is crucial to determine the appropriate size of the bubble mailer. The mailer should be slightly larger than your item to allow for a comfortable fit without bending or compressing the item.

Step 2: Choose the Right Size Bubble Mailer

Based on the measurements taken, select a bubble mailer that provides enough room for your item. It’s important to consider both the size and the thickness of your item. A mailer that is too small may damage your item or burst during transit, while one that is too large can cause the item to move around excessively.

Step 3: Add Extra Protection for Fragile Items

If your item is fragile, consider wrapping it in an additional layer of bubble wrap or packing paper. This step is particularly important for items that are prone to damage from impacts, as the extra cushioning provides added security.

Step 4: Center the Item in the Mailer

Place your item in the middle of the bubble mailer. Ensuring that the item is centered is vital, as it guarantees equal padding on all sides and minimizes the risk of damage from drops or pressure during shipping.

Step 5: Seal the Bubble Mailer Securely

Bubble mailers typically come with a self-adhesive strip for sealing. Carefully remove the strip cover and press along the edges to seal the mailer. Ensure that the seal is strong and the mailer is closed tightly to prevent the item from falling out.

Step 6: Attach the Shipping Label

Finally, attach the shipping label to the bubble mailer. Make sure that the label is placed on a flat surface, is clearly visible, and is securely attached. The information on the label should be accurate and legible to avoid any issues during shipping.

Steps for Packing with Poly Mailers

Step 1: Assess the Size and Shape of Your Item

Begin by evaluating the size and shape of the item you plan to ship. This initial assessment will guide you in choosing a poly mailer that adequately fits your item. Remember, the mailer should be slightly larger than the item to prevent stretching or tearing.

Step 2: Choose the Appropriate Poly Mailer

Select a poly mailer that matches the dimensions and weight of your item. If your item is heavier or has sharp edges, opt for a thicker poly mailer for increased durability. The right mailer not only protects the item but also ensures the integrity of the package during transit.

Step 3: Provide Additional Protection if Needed

For items that need extra protection, such as clothing susceptible to wrinkles or light electronics, wrap them in tissue paper or foam sheets. This step is crucial for items that need protection from scratches, dust, or minor impacts.

Step 4: Place the Item in the Mailer Carefully

Insert your item into the poly mailer, ensuring it fits comfortably. Avoid overstuffing the mailer, as this can stress the seams and lead to tearing. Proper placement of the item is important to maintain the mailer’s integrity and protect the contents.

Step 5: Seal the Poly Mailer Securely

If the poly mailer does not come with a self-adhesive seal, use high-quality packing tape to close it. Ensure that the tape covers all open edges and reinforces the closure, keeping the item secure inside. A well-sealed mailer is critical for preventing accidental openings during shipping.

Step 6: Attach the Shipping Label Properly

The final step is attaching the shipping label. Place the label on a smooth, flat area of the mailer for maximum visibility and scanning ease. The label should contain accurate shipping information and be securely affixed to prevent it from coming off during handling and transit.

Common Mistakes to Avoid When Packing Mailers

Overpacking the Mailer

One of the most frequent mistakes is overpacking the mailer, which can cause it to burst or tear during transit. Always choose a mailer that comfortably fits the item without the need to force it in. This ensures the integrity of the mailer and the safety of the contents.

Inadequate Sealing

Inadequately sealed mailers can open during shipping, leading to lost or damaged items. Whether using a self-adhesive mailer or sealing with tape, ensure that all edges are securely closed and the seal is strong.

Incorrect Labeling

Mislabeling packages can lead to delays or lost items. Double-check the shipping address and other details on the label for accuracy. Also, ensure the label is firmly attached and placed on a flat surface for easy scanning.

Neglecting Fragile Items

Not providing enough cushioning for fragile items is a common oversight. Use additional protective materials like bubble wrap or foam sheets for items that need extra care during shipping.

Choosing the Wrong Type of Mailer

Selecting the wrong type of mailer for your item can lead to damage. Understand the differences between bubble and poly mailers and choose based on the nature and fragility of the item.


Packing items for shipping with bubble and poly mailers can be a straightforward and efficient process when done correctly.

By understanding the appropriate uses of each type of mailer, selecting the right size, ensuring proper cushioning, and sealing and labeling correctly, you can significantly reduce the risk of damage during transit.

Avoiding common packing mistakes, considering environmental impacts, and following a final checklist are also key to a successful shipping experience.

Maxwell Hua

Maxwell Hua | WHpack

Rapid Manufacturing Expert

I’m Maxwell Hua from WHpack, who has been focusing on the Courier Bags business for more than 10 years. I will always be committed to writing articles about the logistics industry, hope this will help you!

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