Custom Poly Mailer Bags

Seal Strips, Tear Lines and Returns

Each bag has a peel-and-seal adhesive strip on the flap, which bonds firmly once pressed and shows signs of tampering if someone tries to reopen it. Packers simply remove the backing and press the flap down, which is far faster than taping a box.

A tear line just below the seal lets customers open the bag neatly without scissors. A second adhesive strip turns the bag into a returns mailer, so customers can reseal it and send an item back without hunting for packaging. For fashion brands with regular returns, that small extra improves the customer experience considerably.

Make sure packers press the whole length of the strip firmly, especially at the corners. A seal pressed only in the middle can lift at the edges, while one pressed end to end stays closed through the roughest courier journey. p2 The returns strip is explained on our tear strip poly mailers page.

Matching Sizes to Your Products

Fashion ranges include everything from a silk scarf to a winter coat, so most brands need three or four bag sizes. Fold your typical orders as you would pack them and measure the flat size, allowing for thickness. A bag that is snug without being stretched gives the neatest, most professional parcel.

Accessories such as jewellery, belts and small bags can go in smaller mailers, sometimes inside a printed box for protection. Bulkier knitwear, outerwear and multi-item orders need larger bags with room for the flap to close without strain.

We quote the usable internal size of each bag, not including the flap, so you can compare sizes accurately.

Think about your packing station as well. A small number of well-chosen sizes, each stored within reach of the packer, speeds up dispatch and reduces the temptation to use a bag that is too big just because it is closest.

If you sell bundles or gift sets, consider a larger bag specifically for those, so items are not squeezed and the parcel arrives looking cared for.

Making the Unboxing Feel Considered

Opening a poly mailer is quick, so the experience inside matters. Many brands wrap garments in tissue paper sealed with a logo sticker, add a thank-you card or a discount code for the next order, and include a returns slip that matches the bag design. Each of these costs little but turns a delivery into a brand moment.

Printing a short message on the inside of the bag, such as a thank-you or a social handle, is another detail customers notice when they tear it open.

Consistency between the bag, tissue, stickers and cards makes the strongest impression. Using the same colour palette and logo position across all of them creates a recognisable look that customers associate with your brand. p2 Tissue in the same shade is covered on our branded tissue paper page.

Choosing Between Mid-Weight and Economy Bags

If your products are low-cost basics sent in very high volumes, an economy bag may be the sensible choice. If your brand relies on presentation and repeat custom, the stronger film, richer colour and better feel of a mid-weight bag usually pay for themselves in fewer damaged parcels and a stronger impression. Some brands use economy bags for single basics and branded mid-weight bags for everything else.

Storage and handling are similar for both. Keep bags flat, cool and out of sunlight so the film and adhesive stay in good condition.

Test both if you are unsure. Sending a few orders in each and checking how they arrive will tell you more than any specification sheet about which bag suits your products and courier. p2 Coats and bundles that outgrow the large size go in our large poly mailers.

Keep the Film Colour Reference With Your Artwork

A signature mailer colour only works if the second order matches the first, and film colour drifts between batches unless there is a reference to hold it to. Send a Pantone number or a swatch with your artwork, keep the sample we send from the first run, and quote both on every reorder. Choose matt for a fashion label and gloss for a bold colour, and decide now if the inside should contrast with the outside.

Size the bags from real orders: fold your common single item, a two-item order and your largest bundle, and send those three measurements with the monthly volume. Ask for a tear line and a second seal strip if returns are part of your business. The custom quote arrives by email within one working day with the minimum set per job.

The free proof shows the logo on each bag size with the label panel clear. Production takes 4 to 7 working days after approval and the bags reach UK mainland addresses by free tracked delivery. Labels that send a lot of basics usually keep an economy poly mailer in thinner film beside the branded bag for those orders.