How To Make Custom Poly Mailers?

WH Global Pack blog

Customization of poly mailers is not a difficult task. You can customize your poly mailers without affecting the lead time and quality of the mailer. That’s why many retail sellers and e-commerce business owners have started using custom poly mailers. The decision seems fair because poly mailers are lightweight, inexpensive, take minimal space, and can easily be customized for marketing.

However, printing anything on a poly mailer can be hard because it is made up of polyethylene. That’s why you must pick an excellent approach to make custom poly mailers. There are various ways to custom print the poly mailers. The suitable method depends on your brand. In this article, I will tell you all the possible ways to custom print the poly mailer. However, if you don’t have the equipment to make custom poly mailers yourselves, you can contact WHpack. They are a reliable manufacturer with affordable pricing and rapid delivery.

What are poly mailers?

Poly mailers are envelopes made up of polyethylene. They are thin, lightweight, and protective in nature. Because of polyethylene, they are durable and water resistant. They come in a variety of sizes and are mainly white or gray in color. However, they are easily customizable, and you can also color print them.

Methods to make custom poly mailers

When it comes to customizing the poly mailers, the print should be waterproof and durable. The print should also be creative and attractive to win customers in the long run. Here are some most famous printing methods with their pros and cons.

  • Inkjet printing
  • Screen printing
  • Flexography
  • Offset printing
  • Rotogravure

Read the description of each method to find out which one is feasible for you.

  1. Inkjet printing

Inkjet printing is the method of computer printing. In this method, the computer propels the ink droplets on the plastic print to create digital images.

However, poly mailers are made up of plastic, so regular water-based ink is not suitable to use on it. That’s why if you are using the inkjet printing method to customize poly mailers, you should use solvent-based ink. This ink will produce a waterproof and smudge-proof print.


  • Fast process. Customization will not affect the time of shipment.
  • Suitable for less quantity of poly mailers.

If you want to custom print only a small number of poly mailers, then an inkjet printer is a good choice. Moreover, if you frequently change the prints of your poly mailers, investing in a semi-professional inkjet printer will save you from finding a retail printer. It will also save your printing costs.


  • Detailed image isn’t possible
  • Bulk printing can be expensive

The right time to use

  • If you change your poly mailer designs frequently.
  • You need fewer number of printing units.
  • Screen printing

Screen printing is an old technique, but this technique is suitable for printing in bulk. In screen printing, you must create a screen with a combination of frame and mesh. The screen will be created on the mailer. Spread the ink on the screen to make the print you want. However, remember that if you’re going to use more than one color, then you need to create as many screens as the number of colors you are going to use.


  • One dedicated screen can be used multiple times and with different colors.
  • Poly mailers of any size, thickness, and dimension can be customized through this technique.
  • Suitable for printing bulk of poly mailers.


  • Time taking method
  • Maximum only two colors can be used in the technique.
  • Although suitable for printing bulk poly mailers, but you can print only one mailer at a time.
  • Requires human intervention
  • Require prepress work

The right time to use

  • When you need to print poly mailers with similar artwork.
  • Suitable for printing brand logos, taglines, and other graphic elements.
  • Flexography printing

Flexography is an updated version of letterpress printing. This method is widely used to print materials like plastic and poly mailers. In flexography printing, there is a flexible plate with a carving design. This plate is used to print the pattern. Moreover, heat rollers can also be used for printing later in seal poly mailers.


  • Durable print and color
  • The same machine can be used for heat sealing poly mailers
  • The machine is compatible with water-based ink
  • Give HD prints with UVC inks


  • Flexography printing system requires setting, tooling, plate making, and mounting (prepress process).
  • If you use water-based inks, then the printing cost will go higher.
  • Not suitable for print requiring more than three colors.

The right time to use

  • Flexography printing is suitable when your poly mailer package needs solid colors over a large surface.
  • Offset printing

Offset printing or offset lithography is among the most popular techniques to custom print poly mailers. Offset printing requires pre-pressing. In the modern day, a computer-to-plate system is introduced in offset printing, which makes the whole process simpler and more accurate.


  • You can print high-definition images
  • One of the most economical methods to custom-make poly mailers in bulk.


  • The image quality is slightly lower than that of rotogravure printing.

The right time to use

  • When you need to print a large number of poly mailers.
  • When you are ready to compromise image quality slightly.
  • When you are tight on budget.
  • Rotogravure printing

In rotogravure printing, the image you want to print on poly mailers is first engraved onto the cylinder. Now the system uses a rotary printing press to print the image design on poly mailers.


  • Poly mailers of various thicknesses can be customized.
  • Give quality results even after the extended use of cylinders.
  • Economical in case of bulk printing.


  • High initial set-up cost

The right time to use

  • When your business requires the printing of thousands of poly mailers.
  • For printing poly mailers in bulk.

Benefits of custom-made poly mailers

In the modern day, beautiful packaging is essential to attract customers to your brand. Your package can act as your marketing ambassador if designed properly. Here are some benefits of custom-made poly mailers:

  • Properly customized poly mailers will set the tone of your brand.
  • Increase your brand awareness.
  • Helpful in avoiding shipment mistakes.
  • Customized poly mailers will distinguish you from your competitors.


With knowledge of how to custom make poly mailers, now you can easily create shiny, matte, shiny-matte combined patterns and different prints on your poly mailers. It’s you who can design and make poly mailers. That’s why you should carefully choose the correct printing method. Carefully evaluate your situation and see how many poly mailers you need before opting for any printing method. Or you can also check out WHpack.

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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