Custom Flexible Kraft Mailers

Sizing Flexible Kraft Mailers for Your Range

Lay your product flat in the way you plan to pack it and measure its length, width and thickness. Add around 20–30 mm to the width and 40–50 mm to the length so the item slides in without a struggle and the flap closes over it cleanly. For thicker items, add the thickness to both the width and the length allowance, since the paper wraps around three dimensions.

Most online sellers manage with two or three sizes. A small one for accessories, a medium one for single garments or books, and a large one for multi-item orders cover the majority of parcels. Fewer sizes mean simpler stock control and a better chance of meeting minimums on each.

If you are unsure, order a short run of two sizes and pack a week of real orders with them. You will quickly see whether the small size is too tight for your thickest items or the large one leaves too much loose paper. It is better to learn that on a small batch than on a full pallet of mailers that do not quite fit. Our guide on how to measure folded garments covers the extra room a mailer needs to close.

Printing on Brown Kraft Paper

Kraft paper absorbs ink differently from white board. Dark colours such as black, navy, forest green and deep red print strongly and look confident against the brown. Pale shades and pastels soften into the paper and can look muted, so if your brand relies on light colours, a white printed panel or a bleached white kraft paper may be the better route.

Most brands print a bold logo on the front and leave space for the shipping label. A small message on the back, such as a thank-you line or a social handle, adds personality without cluttering the parcel. Printing the inside is possible too, and a pattern revealed on opening is a pleasant surprise for the customer.

Remember that couriers handle flexible mailers by hand and stack them in bags. Keep important information away from the seal and the edges, where creasing is heaviest. Our finish guide lists the inks that read on brown kraft and those that disappear.

Packing Tips for Soft Goods

Fold clothing neatly and, if you use tissue paper, wrap the garment before it goes into the mailer. The tissue keeps the fabric clean and makes the opening feel cared for, while the mailer itself does the protective work. Avoid overfilling, as a stretched mailer is more likely to split along the seams.

For books and flat prints, place a sheet of card inside to stop corners bending. For jewellery or small accessories, a little printed card or a small box inside the mailer gives the item structure, and the mailer then acts as the outer shipping layer.

Press out as much air as you can before sealing. A loose mailer with a pocket of air inside is more likely to catch on sorting machines and tear at the corner, while a snug one slides through the network without snagging. Run your hand firmly along the adhesive strip once it is closed, paying attention to the ends, which is where most seals lift.

Place the shipping label on the flat front panel rather than across a fold or gusset. Couriers scan labels many times on the way, and a creased label can cause a misread that delays the parcel. A sheet of tissue paper inside the mailer turns a soft parcel into an unboxing.

Who Uses Paper Mailers Like These

Clothing brands and print-on-demand shops are the largest group, followed by booksellers, stationery sellers and accessory makers. Subscription businesses that send socks, scarves or zines each month like the slim profile, since it keeps postage costs steady. Artists sending unframed prints use flexible mailers with a card stiffener, and small brands selling on marketplaces choose printed mailers so their parcel is recognised among plain ones in the same delivery.

Charities and membership organisations also use them for welcome packs and printed newsletters, where a branded mailer makes a better first impression than a plain envelope.

Repair services and refurbishers sometimes use them for returning small items such as watch straps or phone cases to customers, often with a padded variant. Each of these senders values the same things: quick packing, a slim parcel and a branded first impression at the door. Brands that need a waterproof bag for the doorstep use tear strip poly mailers alongside paper.

Add 30 mm to the Width and 50 mm to the Length

Flexible mailers need room to close over a folded garment, so measure the folded item and add roughly 20 to 30 mm to the width and 40 to 50 mm to the length, plus the item's thickness on each side. For chunky knits choose a gusseted mailer rather than oversizing a flat one. Decide between natural brown kraft, which hides scuffs and suits dark inks, and bleached white for pastel brands. If customers may return items, ask for a second adhesive strip and a tear line. Fragile goods do not belong in a paper mailer; they need a foldable mailer box with rigid walls.

Send the sizes, paper type, print colours and quantity, and a custom quote comes by email within one working day. The free proof shows the print on each face and any inside pattern. Production takes 4 to 7 working days after approval, mailers arrive flat in cartons by tracked courier to UK mainland addresses, and misprints or damage reported within 10 days are reprinted or refunded.