If you're searching for custom poly mailers, you've probably noticed most suppliers offer the same thing: a template, a minimum order of 1,000+, and a 4-6 week wait. We built Teal Packaging to be different.
We make custom poly mailers starting at just 100 units. Every order is custom - your dimensions, your artwork, your brand. No stock sizes forced on you. And we ship free anywhere in the US, typically within 7-14 business days.
Why Brands Switch to Teal for Custom Poly Mailers
The packaging industry ha For related packaging needs, explore our cream packaging.s a dirty secret: most "custom" packaging companies are middlemen. They take your order, send it to the same factories everyone else uses, and mark it up 40-60%. We work directly with our manufacturing partners and pass those savings to you.
Here's what that means in practice:
- Lower prices. Without the middleman markup, our custom poly mailers typically cost 20-35% less than competitors at the same quality level.
- Real customization. Any size, any shape, any finish. We don't limit you to pre-set templates.
- Material variety. Kraft, SBS, corrugated, rigid board - plus specialty options like holographic, textured, and metallic stocks.
- Small batch friendly. 100 unit minimum. Test a design before committing to thousands.
Materials and Specifications
Choosing the right material is half the battle with custom poly mailers. Here's a quick breakdown of what works for different use cases:
Kraft paperboard (300-400 GSM) gives you that natural, eco-friendly look that consumers love. It's strong enough for most retail products and costs less than coated stocks. Best for: artisan brands, organic products, subscription boxes.
SBS ( For related packaging needs, explore our rigid boxes.Solid Bleached Sulfate) is the premium choice. Bright white surface that takes print beautifully, smooth finish, excellent for high-end retail. 280-400 GSM depending on product weight. Best for: cosmetics, luxury goods, food packaging.
Corrugated board (E-flute or B-flute) adds serious structural protec For related packaging needs, explore our soap boxes.tion. E-flute is thinner (about 1.5mm) and great for mailer boxes. B-flute (about 3mm) handles heavier items. Best for: e-commerce shipping, fragile products, stacking needs.
Rigid board (1000-2000 GSM) is the luxury option. Thick, sturdy, won't flex. Used for phones, jewelry, premium spirits. More expensive per unit, but the unboxing experience is unmatched.
Printing Options
Every custom poly mailers order gets full-color CMYK printing with soy-based inks. But that's just the starting point:
- Spot UV coating adds a glossy, raised effect to specific elemen For related packaging needs, explore our corrugated packaging.ts (logos, text, patterns). Creates contrast against matte backgrounds.
- Foil stamping in gold, silver, rose gold, or custom Pantone metallic colors. Hot foil for sharp detail, cold foil for larger coverage areas.
- Embossing/debossing creates a raised or recessed texture. Combine with foil for a premium look.
- Soft-touch lamination gives a velvety, matte feel. Popular for luxury and cosmetic packaging.
- Window patches let customers see the product inside. Die-cut openings with clear PET film.
Sizing and Structure
We don't do "standard sizes only." Tell us your product dimensions and we'll engineer the box around it. That said, here are common size ranges for custom poly mailers:
- Small: 2x2x1" to 4x4x3" (cosmetics, jewelry, small electronics)
- Medium: 5x5x3" to 8x8x4" (candles, food items, gifts)
- Large: 10x8x4" to 16x12x6" (apparel, multi-item sets, retail displays)
- Custom: literally any dimension you need
Structural options include tuck-end, auto-lock bottom, sleeve-and-tray, magnetic closure, and more. If you're not sure which structure works best, send us your product details and we'll recommend the right option. For related packaging needs, explore our retail packaging.
Eco-Friendly Options
Every material we use is FSC-certified. Our inks are soy-based, not petroleum-based. But if sustainability is a core part of your brand, we can go further:
- 100% recycled content paperboard
- Compostable and biodegradable coatings (replacing standard PE lamination)
- Unbleached, uncoated kraft for zero-chemical-process packaging
- Soy-based adhesives for fully recyclable construction
We'll also help you add the right recycling symbols and certifications to your packaging so your customers know exactly how to dispose of it.
How to Order Custom Poly Mailers
- Request a quote. Fill out our form with your dimensions, quantity, material preference, and any special finishes. Takes about 2 minutes.
- Review your quote. We respond within 24 hours with itemized pricing, material recommendations, and a production timeline.
- Approve your proof. Our design team creates a digital mockup. You get unlimited revisions until the design is exactly right.
- Production. 7-14 business days from proof approval. We send progress updates along the way.
- Free shipping. Delivered to your door, anywhere in the US. No shipping fees, no surprise charges.
Pricing
Custom Poly Mailers pricing depends on four factors: size, material, print coverage, and quantity. A basic kraft box with single-color print might run $0.30-0.80/unit at 500 qty. A fully printed SBS box with foil stamping and soft-touch lamination might be $1.50-4.00/unit. Volume discounts start at 500 units and get steeper at 1,000 and 5,000.
The fastest way to get exact pricing? Request a quote. We'll break down every cost so you know exactly what you're paying for.